Terrafugia Transition: SolidWorks and CATIA Composites for Roadable Aircraft

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Terrafugia Transition: SolidWorks and CATIA Composites for Roadable Aircraft

Case study showing how Terrafugia used SolidWorks and CATIA Composites Design to develop a lightweight, road-legal aircraft while reducing weight and development time.

Published

June 4, 2026

Read time

3 min read

Source

Terrafugia applied Dassault Systemes SolidWorks for mechanical assemblies and CATIA Composites Design integrated with Simulayt for composite lay-up optimization on its Transition roadable aircraft. The tools enabled virtual testing, accurate fiber orientation analysis, and direct export of ply data to manufacturing. Results included significant weight reduction versus the proof-of-concept vehicle, elimination of trial-and-error on the shop floor, and faster progression toward FAA Light Sport Aircraft certification.

Key takeaways

SolidWorks handled complex mechanical assemblies and imported off-the-shelf component models to accelerate design.

CATIA Composites Design with Simulayt enabled ply-by-ply analysis and draping simulation to minimize weight without sacrificing strength.

Accurate flat-pattern generation and ply books reduced material waste and transferred design data directly to production.

Virtual structural analysis replaced over-design practices, cutting prototype iterations and overall vehicle weight.

Integration of design and analysis supported self-certification to FAA Light Sport Aircraft and NHTSA standards.

Market overview

SCR methodology note

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