In a recent incident during a test flight, an aircraft suffered structural failure after a propeller blade detached due to adhesive bond failure. The aircraft, remotely piloted and conducting a test flight at 30 feet above ground level, experienced a series of failures that led to its eventual descent and subsequent damage upon striking the ground.
The aircraft, identified as G-EVTL, was undergoing its 123 to the aircraft’s wiring harnesses.
Despite attempts by the flight control system to maintain a level attitude, the loss of vertical thrust from motors 4 and 7 caused the aircraft to descend rapidly, leading to substantial damage upon impact with the ground.
The aircraft’s manufacturer was in the process of introducing a new blade design to address the bonding failure mode that caused the blade release. The manufacturer’s investigation into the incident identified 36 product and process improvements, including enhancements in quality control, design, and verification processes.
The accident highlights the importance of rigorous testing and continuous improvement in aircraft design and manufacturing processes to ensure safety and reliability during flight operations.
