I conducted work experience at Ryan Aerospace, as part of my external IAP thesis project.Ryan Aerospace specialize in the design and manufacture of cost-effective commercial off-the-shelf (COTS) helicopter simulation. For my thesis project, I was tasked with designing, developing and manufacturing a prototype LCD instrument panel to be fitted into a (real) Robinson R-22 helicopter cockpit to be used as a simulator.This involved:• Identifying the user needs, requirements and defining the design input specifications.• Generating concepts based on the main components and evaluating them.• I was required to respond to the project brief with a full project plan including GANTT chart, methodologies, budget, bill of materials etc.• Source instrument components (LCD’s,button,switches, knobs, screw, bolts, encoders, etc)• Adopting the Food and Drug Administration's (FDA) Waterfall Model for the Methodology/Design process.• Developing fully working 3D CAD models in Solidworks.• Finite Element Analysis of vital load bearing sheet metal components.• Developing 2D engineering drawings of each component for manufacturing.• Professionally manufactured using laser cutting, water jet cutting, Sheetmetal bending, turning and milling.• Assembly, testing and quality control of the final manufactured helicopter simulator instrument Panel.• Through this project I was able to achieve the highest Grade possible of High Distinction for my Thesis.