Design
The Solar Challenger was designed to be sturdier, more powerful, and more maneuverable than the Gossamer Penguin so as to be able to withstand sustained high altitude flight and normal turbulence. It was over three times as heavy (without pilot) as the Gossamer Penguin and had a shorter wingspan, but was proportionately more powerful, with electricity supplied by 16,128 solar cells powering two three-horsepower motors. The solar panels were directly affixed to the wing and large horizontal stabilizer, both of which had to be flat on top to accommodate them. The two motors, each 3 inches wide and 17 inches long and incorporating samarium-cobalt permanent magnets, operated in tandem on a common shaft to drive a single, controllable pitch propeller. The design incorporated advanced synthetic materials with very high strength to weight ratios, including Kevlar, Nomex, Delrin, Teflon, and Mylar, all supplied by the aircraft's sponsor, Dupont.
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