Initial Sizing in Hand Calcs

Course Length:



$1495 per person


This intensive, two-day course provides the attendee with directly applicable tools to get their jobs done. The emphasis is on tactical execution of structural sizing during the initial phases of a design to ensure the concepts will meet the requirements when more thorough analysis is completed later. The methods are all presented as functions to aid the attendee in understanding the influence of the various design parameters that drive sizing of the structure. In additional to the presentation and equations, digital copies of references are provided with Excel and MathCAD versions of the solutions provided to allow implementation of the methods immediately. Each topic presented could be extended to one or more days of training. In fact, some topics are routinely given as multi-day sessions. This course is not like that and instead provides an 80/20 rule solution for most configurations seen in production and then provides the resources for the designer and analyst to investigate further as required. By emphasizing fast, accurate, and easy to understand sizing rules, designs are set on the correct trajectory early in the development phase thereby reducing or eliminating the need for costly redesigns later. Worked examples and hands-on class problems are presented.

Course Outline:

  1. Problem Setup – Thinking like a Stressman. The importance of FBD’s and the drawing of problems, identifying components and failure modes, and sizing rules of thumb.
  2. Loads and Loads Determination. Generating load cases from requirements and sizing with unknown loads..
  3. Mechanics of Materials Primer. Basic stress equation refresher with typical safety factors, writing margins, and recommended references.
  4. Materials & Material Allowables. Where to find material properties and determine A and B-basis strength allowables.
  5. Metallic Bolted Joints. Rules of thumb for joint sizing, failure modes, typical torque values, tolerancing, joint slipping and gapping.
  6. Composite Bolted Joints. Hart-Smith joint guidance, bearing-bypass failure modes, strength corrections, joint testing, and lessons learned.
  7. Lugs. Classical lug analysis and guidelines
  8. Sizing and Analyzing Welds. Steel and aluminum welding, HAZ, and line load methods.
  9. Bonded Joints. Pros/Cons of adhesive joints, recommended joint types, classic equations for single/double lap joints, FEM methods.


If this course is not on the current schedule of open enrollment courses and you are interested in attending this or another course as an open enrollment, please contact us at (410) 956-8805 or Please indicate the course name, number of students who wish to participate. and a preferred time frame. ATI typically schedules open enrollment courses with a 3-5 month lead time. For on-site pricing, you can use the request an on-site quote form, call us at (410) 956-8805, or email us at


  • Eric Roulo has been an aerospace structural analyst for 18 years working on satellites, rockets, and commercial and military aircraft systems. As a consultant, he has worked on target and Orbital rockets, Global Hawk, Predator, commercial and NASA satellites, and numerous weapons systems. Since 2006 he has trained 100’s of engineers both on-site and at public courses. Eric brings a unique perspective to the classroom with production level tools, broad industry experience, efficient methods, extensive references, and provided solution templates.

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