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This paper presents a certification-driven design process for an Unmanned Medium-Altitude-Long-Endurance (UAV MALE) air vehicle, including on-board system design and placements, electro-magnetic compatibility analysis, and thermal risk assessments. In literature, the preliminary aircraft design phase is mainly driven by mission performances and structural integrity aspects. However, the inclusion of other disciplines, like on-board system design or electro-magnetic compatibility, or thermal analysis, can lead to more efficient and costeffective solutions and becomes paramount for non-conventional configurations like unmanned vehicles or highly electrified platforms. In the EC-funded AGILE 4.0 project (2019-2022), the traditional scope of the preliminary aircraft design is extended by including domains that are usually considered only in later design phases, such as certification, production and maintenance. In this paper, the AGILE 4.0 design environment supports the definition and execution of a certification-driven design process of a UAV MALE configuration, using a Model-Based Systems Engineering (MBSE) approach.

This paper demonstrates a stacking sequence optimisation process of a composite aircraft wing skin. A two-stage approach is employed to satisfy all sizing requirements of this industrial sized, medium altitude, long endurance drone. In the first stage of the optimisation, generic stacks are used to describe the thickness and stiffness properties of the structure while considering both structural requirements and discrete guidelines such as blending. In the second stage of the optimisation, mathematical programming is used to solve a Mixed Integer Linear Programming formulation of the stacking sequence optimisation. The proposed approach is suitable for real-world thick structures comprised of multiple patches. Different thickness discretisation strategies are examined for the retrieval of the discrete stacking sequences, with each one having a different influence on the satisfaction of all structural constraints across the various sub-components of the wing. The weight penalty introduced between the continuous and final discrete design of the proposed approach is negligible.