VFS STEM Program

LEGO-neering: Teaching K-12 Students about Vertical Flight Engineering through the Usage of Custom LEGO Models

Recently, a group of undergraduate Aerospace Engineering students at Penn State University has been involved in an innovative project to engage K-12 students in engineering using custom- built LEGO models. Thus far, 8 individual models have been designed and assembled to teach students about various vertical flight engineering topics. These models teach about relevant aerospace principles such as power transmission, gearing, structures, and mechanical redundancy.

Thus far, the LEGO models have been used in several presentations to pre-college students in various grades. Each demonstration catered to the specific age of those listening. Ideally, students listening to the presentations will develop an increased interest and knowledge in vertical flight engineering. Future efforts by the Penn State team will be made to quantitatively assess changes in engineering interest and knowledge before and after the LEGO models were shown to students.

Project History

The LEGO-neering project originated with a meeting between Penn State Aerospace Engineering Professor Edward Smith and undergraduate Aerospace Engineering student Alex Duffy. They first decided to design and build two models of coaxial helicopters. These models were created with the BrickLink Studio 2.0 software, which gives users access to a virtual database of all LEGO pieces. These pieces can be compiled into a virtual 3D visualization of a LEGO model. Once the virtual model is created, the pieces for it can be ordered online at the BrickLink marketplace where private sellers can sell new and used LEGO pieces.

The first two coaxial helicopters were created in an iron bird configuration. This setup was chosen to demonstrate the internal functionality of this helicopter type. Both coaxial models were identical, apart from one having a single LEGO motor and the other having two motors. The purpose of designing two models in this way was to explain the concept of redundancy. When the single-motor coaxial model is powered on, the model can be made to stop spinning when its only motor is deactivated. For the dual motor model, when one of the two motors is made to stop working, the rotors keep spinning. A side-by-side comparison of the two models can be used to effectively demonstrate the safety benefits of having two motors on a helicopter instead of one. These models also showcase the gearing of a coaxial helicopter.

Following the creation of the dual motor models, an iron bird recreation of a tiltrotor aircraft was designed and fabricated. This model featured a motor under each tilting nacelle. If one of the two motors was made to stop working, then a driveshaft from the working rotor transmitted power to the other rotor whose motor was deactivated. This further demonstrates the redundancy that is built into modern tiltrotor aircraft.

Five more models were also created that showcase the design of various eVTOL aircraft. The vehicles that were replicated are the NASA Dragonfly lander, the Wisk Generation 6 aircraft, and the Joby S4 aircraft. Three versions of the Dragonfly lander were created for display and educational demonstration purposes. The educational version of the model features rotating blades, a pivoting radar, and a radioisotope thermoelectric generator replica. This model was used to educate students about the NASA Dragonfly mission.

The Wisk eVTOL model has limited functionality apart from its ability to tilt its rotors 90 degrees. This creation was meant to realistically replicate the exterior of the aircraft. The Joby eVTOL, however, demonstrates the technical functionality of the S4 vehicle. This was built in an iron bird configuration and shows how each rotor is powered by its own motor.

So far, Samay Shingatwar and Alex Duffy have been responsible for designing and building the models. Their design process for each was the same: first using the Studio 2.0 software, then ordering the pieces for the model based on their digital design, and finally building the model according to the rendering.

Outreach Efforts

So far, five undergraduate Aerospace Engineering Students have been involved in the project: Sarah Bock, Alex Duffy, Adi Nagarajan, Rachel Shifflett, and Samay Shingatwar. These students have all volunteered to either design the models or present them to students.
The first outreach event occurred at a middle school in Northeast Pennsylvania. The two coaxial and tiltrotor models were presented to students at both the 5th and 6th grade levels. The students were first given an overview of the respective aircraft configurations and were then given a demonstration of the models. After being shown the demonstrations, many students correctly identified the purpose of having two motors on a helicopter. The design process for both models was also outlined and compared to the engineering design process. By doing so, a connection was made between building with LEGO and engineering.

A similar demonstration was given to high school students in Central Pennsylvania. This presentation was delivered in a way to better cater to the older students, but still taught the same message as the one given to the middle schoolers. This presentation also featured the demonstration of the model Dragonfly.

Two more presentations were also given to young students at the elementary and middle school levels. These occurred at the Penn State Vertical Flight Society’s annual STEM Rotor Day and a STEM camp near Penn State’s University Park campus.

In the future, the LEGO-neering team hopes to measure the effectiveness of their educational outreach efforts. By measuring a change in engineering interest and knowledge, the team hopes to assess the effectiveness of their presentation in achieving its goals.