Define the aircraft type and mission requirements
Study aerodynamics, structures, propulsion, avionics, and regulations
Create preliminary sketches and 3D CAD models
Calculate lift, drag, weight, balance, and stability
Select materials for the airframe and control surfaces
Design the wing, fuselage, tail, landing gear, and cockpit
Design the propulsion system and fuel or electrical system
Design flight controls, wiring, instrumentation, and avionics
Build scale models and run simulations
Fabricate prototype parts and assemble the airframe
Install systems, controls, and safety equipment
Perform ground tests and inspections
Conduct flight testing with qualified personnel
Refine the design and correct any issues
Obtain all required certifications and approvals
Produce the aircraft using controlled manufacturing processes