Initial Sizing and Hand Calculations

For Mechanical Designers and Analysts

Using fast, accurate, and easy to understand sizing rules, designs can be set on the correct trajectory early in the development phase, reducing or eliminating costly redesigns later.

In this training we take a comprehensive look at the tactical execution of structural sizing during the initial phases of a design, to ensure the concepts will meet the requirements when more through analysis is completed later.

We will identify the 80/20 rule solutions for most configurations seen in production. The methods are presented as functions to demonstrate the influence of the various design parameters that drive the sizing of the structure.

In addition to presentation and equations, digital copies of references are provided with excel and MathCAD versions of the solutions provided to allow the users to implement the methods immediately.

Who is this training for?

Design and analysis engineers with 2-5+ years of experience benefit the most from this course, while managers and more senior people will get a refresher and have the advantage of a complete framework in which to train.

Key takeaways:

– Tactical execution of structural sizing
– Easy to implement sizing rules
– Structural sizing during initial design phase
– Rule solutions for most production scenarios

Book this training

Public Boot Camp: Thursday 29 October 2020

Join in person in Manhattan Beach, CA or remotely online
Contact us on (855) 724-8811 or at to book your seat


  1. Problem Setup – Thinking like a Stressman
  2. Loads and Loads Determination
  3. Mechanics of Materials Primer
  4. Materials & Materials Allowable
  5. Metallic Bolted Joints
  6. Composite Bolted Joints
  7. Lugs
  8. Sizing and Analyzing Welds
  9. Bonded Joints
  10. Sizing of Beams
  11. Sizing of Plates and Scaling Rules
  12. Ultimate Analysis
  13. Bearing Details & Detrimental Yield
  14. Buckling and Stability
  15. Sandwich Panels
  16. Potted Inserts
  17. Intro to Composite


Eric Roulo, Roulo Consulting President

Eric Roulo has over 20 years of experience in aerospace, defense, and transportation analysis consulting and training with companies including Raytheon, NASA, SpaceX and Virgin Galactic. He started his career at Space Systems/Loral, supporting most of the major primes on projects including military and commercial airplanes, spacecraft, and rockets. He has a Bachelor of Science in Mechanical Engineering and has secured a patent for active steering of an appendage on a spacecraft using piezoelectric actuators.

Attendees receive:

  • Presentation slides
  • Tools and templates
  • Real world project examples
  • Laminated cheat sheets
  • Completion certificate

The Roulo Consulting Initial Sizing and Hand Calcs course was great. I really love how it brings practicality and consciousness of cost into performing analysis and getting the 80% solution at the bottom level. All junior Structural Analysts would benefit from taking this course near the beginning of their career.

– Analysis Manager