Unit 20: Boeing 737 MAX MCAS Accidents (2018–2019) | STEM Aeronautical Systems

Investigate the most significant aviation safety crisis of the 21st century with this complete 6-page printable STEM Case Study Packet! Designed specifically for middle and high school classrooms, this unit provides a deep, informative look at the 2018–2019 Boeing 737 MAX MCAS Crises (Lion Air Flight 610 & Ethiopian Airlines Flight 302), Maneuvering Characteristics Augmentation System (MCAS) software logic, single Angle of Attack (AoA) sensor dependency, aerodynamic trim wheel forces, software flight control overrides, and aeronautical engineering safety ethics. What’s Included in this 6-Page Deep-Dive Packet: Page 1: Historical Case Study & Technical Breakdown – Full historical narrative of the 2018 and 2019 disasters, CFM LEAP-1B engine placement shifts, high Angle of Attack (AoA) aerodynamic stalls, MCAS automated nose-down trim commands, single-sensor failure points, pilot manual overrides, and comprehension check questions. Page 2: Day in the Life Scenario Challenge – Students step into the shoes of a Flight Deck Systems Inspector analyzing real-time cockpit telemetry logs, faulty AoA vane readings (+20 degree discrepancy), repeated automated stabilizer trim activations, manual trim wheel jamming, and emergency flight control protocols. Page 3: Hands-On Unplugged Simulation & Applied Math – Simple step-by-step math calculations comparing manual yoke column forces vs electric stabilizer trim authority, aerodynamic trim force multiplication at high airspeeds (knots), and repetitive 10-second MCAS activation nose-down pitch angles. Page 4: Engineering Ethics & Workplace Dilemma – Omitting safety features from pilot training manuals vs speed to market: analyzing the decision to omit MCAS descriptions from pilot flight manuals to avoid simulator re-training costs, single-sensor system architectures, regulatory delegation (ODA), and aviation oversight reform. Page 5: Redesign Brief & Innovation Lab – Creative blueprinting assignment where students design "Boeing 737 MAX Flight Control Architecture V-2," featuring dual-vane Angle of Attack voting logic, hardcoded software trim limits, pilot manual column override priority, and synthetic airspeed sensor cross-checks. Page 6: Teacher Answer Key & Scoring Rubric – Complete answer key for all questions and math problems, plus a 10-point grading rubric on Page 6 for evaluating student work on Page 5. Teacher Benefits: 100% Unplugged & Copy-Paste Friendly – Clean text layout with zero dark background boxes, code block syntax, or special math symbols for seamless editing in Word, Google Docs, or Canva. Multi-Day Classroom Value – Covers 3 to 5 full class periods; perfect for Physics, Aerospace Engineering, Physical Science, Computer Science, CTE electives, or emergency sub plans. Highly Engaging Content – Combines aerodynamic force math, flight deck telemetry diagnostics, aviation ethics roleplay, and flight control software redesign!