• Become a Premium Member today!

    Welcome aboard HomebuiltAirplanes.com, your destination for connecting with a thriving community of more than 10,000 active members, all passionate about home-built aviation.

    For a nominal fee of $99.99/year or $12.99/month, you can immerse yourself in this dynamic community and unparalleled treasure-trove of aviation knowledge.

    Why become a Premium Member?

    • Dive into our comprehensive repository of knowledge, exchange technical insights, arrange get-togethers, and trade aircrafts/parts with like-minded enthusiasts.
    • Unearth a wide-ranging collection of general and kit plane aviation subjects, enriched with engaging imagery, in-depth technical manuals, and rare archives.

    Become a Premium Member today and experience HomebuiltAirplanes.com to the fullest!

    Upgrade Now

Van's Aircraft Laser Cut Hole Fatigue Analysis

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.


Well-Known Member
Supporting Member
Jun 26, 2012
Calgary, Alberta, Canada
Excellent 2 hour vid on how they tested this and arrived at their recommendations: Van's Engineering Presentation: Testing Analysis and Results for Laser-Cut Parts - Van's Aircraft Total Performance RV Kit Planes

Tip: watch at 1.5X speed and slow down at points of interest.

I learned a lot from this. Interestingly, the manufactured cracks at dimples don't seem to propagate.

Now they've established some pretty long airframe life here however we know plenty of things have cracked across all models of RVs in only hundreds of hours in some cases. My feeling from this is that they may have not fully appreciated vibration effects here from the engine and propeller beat though mentioned in 2 areas of the video as acoustic effects. Their take was low stress but high cycles. High stress generally drives crack propagation. Just what is causing many of the cracks that have appeared in RVs historically then?