Engineering Analysis Report - Public Summary (Redacted)

Air Vision Systems | Public Summary (Redacted)

Contents:

1. 1. Purpose and scope
2. 2. Wind loading basis (public)
3. 3. Bonding approach (public)
4. 4. Key outcomes (high-level)
5. 5. Selected figures (redacted)
6. 6. Conclusion and limitations

1. Purpose and scope

This public summary describes a one-way fluid-structure interaction (FSI) assessment of a low-profile aluminium Starlink roof mount bonded onto a fibreglass vehicle roof under extreme aerodynamic loading. It gives a transparent, high-level overview of the engineering work without disclosing proprietary modelling detail.

2. Wind loading basis (public)

The mount was assessed at a Category 5 equivalent wind speed of 275 km/h, evaluated at 0, 45 and 90 degree yaw angles. The 45 degree (quartering) case produced the worst-case localised loading and was used to set the safety limits. Detailed pressure fields and full contour ranges are withheld.

3. Bonding approach (public)

The mount uses a dual-adhesive bond combining a structural acrylic foam tape with a structural silicone to transfer aerodynamic loads into the fibreglass vehicle roof. Specific adhesive product identifiers and full material property datasets are withheld.

4. Key outcomes (high-level)

• Peak equivalent stress in the adhesive interfaces was 0.225 MPa under the bounding (45 / 90 degree) case.
• This provides a minimum factor of safety of 2.13 against the most conservative adhesive performance limit in the joint.
• Global deformation remained negligible (sub-millimetre).
• The aluminium mount itself was structurally unaffected, so performance is governed by the adhesive bond rather than the mount.

5. Selected figures (redacted)

The figure below illustrates a representative output. Detailed CFD pressure fields, meshing images, and full contour ranges are intentionally excluded.

6. Conclusion and limitations

The analysis confirms the bonded aluminium mount on a fibreglass roof is structurally sound under 275 km/h aerodynamic loading. The dual-adhesive configuration transfers the dynamic loads into the vehicle roof without exceeding material limits, with a substantial safety margin. Achieving this performance depends on correct surface preparation during installation. This public summary omits detailed model construction, material datasets, meshing, solver controls, and pressure mapping; it is general guidance and not a substitute for project-specific engineering sign-off.