Airworthiness certification is an indispensable link in the launching process of civil aircraft. According to the airworthiness regulations, the test aircraft are required to complete the flight test with simulated ice, which is a test flight course with class I risk, to examine comprehensive aerodynamics and operational stability of the aircraft. Because of the severe difficulty and high risk of real icing flight tests, it is extremely important to carry out research and design of simulated ice. Taking the natural icing process of a civil aircraft wing as the research object, we first determine the critical ice type of the research aircraft, design the simulated ice structure, and utilize the 3D printed sandwich material to fabricate the simulated composite ice. The aerodynamic load of the ice model under extreme working conditions is then obtained via CFD simulation, and the finite element analysis employed to acquire the damage strength and failure modes of the simulated ice. The effectiveness of the simulation results and, subsequently, the feasibility of the structural design of simulated ice with 3D printed sandwich composite are verified by the quasi-static test.
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