Flitecad Repack (LEGIT — WORKFLOW)

This is the secret sauce. FliteCAD calculates how to split that 3D curved surface into a top skin and a bottom skin. Because foam board cannot stretch like plastic wrap (it will crumple), FliteCAD calculates "darts" or "relief cuts"—small triangular cutouts that allow the flat foam to approximate a curved surface.

FliteCAD is a specialized computer-aided design (CAD) software developed by Adam Hall Group

: Start by entering the internal dimensions of the equipment you need to protect. Select Case Type flitecad

Here is the clarification based on typical usage of that software:

FliteCAD fills this niche. It is a parametric design tool tailored for the manipulation of tubes, joints, and geometric shapes common in the construction of paramotor cages. It allows designers to visualize, modify, and calculate the physical properties of a frame before a single piece of metal is cut. This is the secret sauce

FliteCAD is an open-source, script-based design tool specifically engineered to convert 3D models into 2D foam board cut patterns. While traditional CAD software (like Fusion 360 or SolidWorks) is designed for machining or injection molding, FliteCAD is built for the unique properties of foamboard: the paper skin, the 45-degree bevel cuts, and the "A/B fold" technique popularized by the Flite Test community.

Paramotor frames are complex 3D structures often made of bent aluminum or titanium tubing. Creating these curves in standard CAD software can be tedious. FliteCAD simplifies this with specialized bending tools that allow designers to manipulate tube paths intuitively. You can define anchor points (where the harness attaches, where the engine mounts) and let the software generate the connecting tubing geometry, ensuring smooth curves that maintain structural flow. It allows designers to visualize, modify, and calculate

It calculates cut dimensions, total weight, construction time, and sales prices in seconds.

: Produces a detailed list of all required parts (extrusions, panels, hardware) and their specific cutting measurements. 2D & 3D Visualization

FliteCAD is a Computer-Aided Design (CAD) software developed specifically for the paramotor and ultralight aviation industry. While general-purpose CAD programs like AutoCAD or SolidWorks are powerful, they come with steep learning curves and generic toolsets not optimized for the specific geometries of a paramotor frame.

While traditional 2D or 3D CAD programs like AutoCAD or FreeCAD offer broad design capabilities, they often lack the parametric tools specific to flight cases—such as automatic placement of rivets, extrusions, and hardware. General CAD Software Flight case manufacturing General engineering/design Component Library Extensive Adam Hall Hardware User-created or generic libraries Business Logic Integrated pricing & labor costs Requires external spreadsheets Output Precise cutting lists & BOMs Standard technical drawings Advancing Your Workflow