Boeing 737 MAX MCAS Accidents STEM Case Study

Investigate the most significant aviation safety crisis of the 21st century with this comprehensive, no-prep 6-page printable STEM Case Study Packet! Designed specifically for middle and high school classrooms, this multi-day unit provides an immersive, highly informative look at the 2018–2019 Boeing 737 MAX MCAS Crises (Lion Air Flight 610 and Ethiopian Airlines Flight 302). By combining aeronautical engineering principles, flight deck telemetry troubleshooting, aerodynamic force calculations, and software design ethics, this resource transforms a major aerospace tragedy into a rich, interactive learning experience.

Throughout this unit, students explore critical secondary STEM concepts—including engine placement pitching moments, Angle of Attack (AoA) sensing, automated horizontal stabilizer trim authority, manual trim wheel mechanical leverage, pilot override logic, and safety-critical software redundancy—in an accessible, highly engaging format.

What’s Included in this 6-Page Deep-Dive Packet:

• Page 1: Historical Case Study & Technical Breakdown

  Features a detailed historical narrative of the 2018 and 2019 disasters. Students examine the physical shifts of CFM LEAP-1B engines, high Angle of Attack aerodynamic stall tendencies, automated MCAS nose-down trim commands, single-sensor failure points, and pilot manual override challenges before answering targeted comprehension check questions.

• Page 2: Day in the Life Scenario Challenge

  Students step into the shoes of a Flight Deck Systems Inspector evaluating flight telemetry logs. In this realistic roleplay assignment, they analyze faulty AoA vane readings (+20 degree discrepancy), trace repeated automated stabilizer trim activations, evaluate manual trim wheel lockout conditions, and assess emergency flight control protocols.

• Page 3: Hands-On Unplugged Simulation & Applied Math

  Brings flight physics and aerodynamics into the classroom with clear, step-by-step calculations. Students compare manual yoke column forces versus electric stabilizer trim authority, calculate aerodynamic trim force multiplication at high airspeeds, and evaluate repetitive 10-second MCAS activation pitch angles.

• Page 4: Engineering Ethics & Workplace Dilemma

  Explores corporate speed-to-market pressure versus pilot safety transparency. Students analyze the decision to omit MCAS descriptions from flight manuals to avoid simulator retraining requirements, single-sensor system architecture risks, regulatory delegation oversight, and subsequent aviation policy reforms.

• Page 5: Redesign Brief & Innovation Lab

  A creative blueprinting challenge where students act as chief flight control systems engineers designing "Boeing 737 MAX Flight Control Architecture V-2." Applying fail-safe avionics principles, they incorporate dual-vane Angle of Attack voting logic, hardcoded software trim limits, pilot manual column override priority, and synthetic airspeed cross-checks.

• Page 6: Teacher Answer Key & Scoring Rubric

  Includes complete, step-by-step solutions for all narrative comprehension questions and mathematical calculations, along with a clear 10-point grading rubric to streamline assessment for the design blueprint assignment.

Teacher Benefits:

• 100% Unplugged & Copy-Paste Friendly: Clean layout with zero dark background boxes or awkward formatting, ensuring seamless editing in Google Docs, Word, or Canva.

• Multi-Day Classroom Value: Designed to cover 3 to 5 full class periods. Perfect for Physics, Aerospace Engineering, Physical Science, Computer Science, CTE electives, or emergency sub plans.

• High-Interest Real-World Content: Combines aerodynamic force math, flight deck telemetry diagnostics, aviation ethics roleplay, and flight control software redesign into one high-impact unit.