The Wright Brothers were many things: pioneers, the first aviators, scientists, engineers, businessmen and safety professionals. That last one may surprise you. In this post I am going to explain how they managed risk better than any of their contemporaries, and how it was a significant factor in their ultimate success.
But first, let’s get lost in their triumph of flight!
“The Wright Brothers succeeded where so many others across centuries failed because of their principled scientific approach, their unique aptitude for identifying and solving the critical problems of controlled flight, actualized by their recognition and control of risk. Their methods enabled the wonderous world of aviation that we enjoy and depend on to this day.”
-Chet Brandon, Instrument Pilot
The Wright’s Engineering of Controlled Flight
The Wright brothers, Wilbur and Orville, pioneered controlled, powered flight by systematically solving the key challenges of aviation—lift, propulsion, and control. Through years of glider experiments and wind tunnel testing, they developed an efficient wing design and a revolutionary three-axis control system, allowing stable and maneuverable flight. They also engineered a lightweight internal combustion engine and custom propellers, optimizing their aircraft’s performance. Their critical moment of success came on December 17, 1903, at Kill Devil Hills, North Carolina, when Orville piloted the Flyer for 12 seconds, covering 120 feet—the first sustained, controlled, powered flight in history. This breakthrough laid the foundation for modern aviation, proving that human flight was not only possible but practical.
Harry Combs, in Kill Devil Hill: Discovering the Secret of the Wright Brothers, highlights several key reasons for the Wright brothers’ success in achieving sustained and controlled flight. Harry was a pilot, engineer and aerospace executive who studied the Wrights legacy with the knowledgeable eye of an aviation insider. His book is written from the perspective of an engineer looking through the lens of an aviator. He describes the technical challenges faced and boundary-breaking solutions the Wrights developed in bring humanity the gift of flight. Below are some of the deep insights he shares.
Unlike other inventors of their time, who primarily focused on building engines with enough power to lift an aircraft, the Wrights approached flight as an engineering problem, recognizing that control was the most critical challenge. They understood that simply getting an aircraft into the air was not enough—it had to be stable, maneuverable, and safe. Their focus on controlled flight set them apart from other aviation pioneers, many of whom dismissed this aspect as secondary.
But first, the Wrights’ has to reach the conclusion that all of the existing engineering data on airfoil wings was incorrect, and then determine the methods to generate their own accurate data. In 1902 the Wrights’ came to this conclusion: “The calculations on which all flying machines had been based were unreliable, and… every experiment was simply groping in the dark… We cast it all aside and decided to rely entirely upon our own investigations.” After this watershed moment, they began a disciplined and engineering based process of understanding and quantifying the lift capabilities of a great number of simple and airfoil wing configurations via wind tunnel testing. This leap in methods and knowledge was critical to the successful design of future aircraft and the Wrights’ were THE pioneers of the science that would become Aerodynamics, leading to commercial air travel and then space travel in an incredibly short 60 years.
To achieve this, they developed a unique three-axis control system—wing-warping for roll, an elevator for pitch, and a rudder for yaw—which allowed the pilot to maintain balance and execute turns effectively. This system became the foundation of modern aircraft control. Instead of relying on brute force to keep an aircraft in the air, they ensured that the pilot could make precise adjustments mid-flight, making their designs both practical and functional. Before adding an engine, they spent years testing and refining glider designs, systematically improving their control mechanisms and gaining essential piloting experience. This hands-on approach allowed them to understand how an aircraft responded to various forces in flight, something that many of their competitors lacked.
Another critical factor in their success was their use of wind tunnel testing. While others relied on flawed theoretical calculations, the Wrights built and used a wind tunnel to test over 200 different wing shapes. This meticulous experimentation provided more accurate data on lift and drag, leading to more efficient wing designs. Their emphasis on aerodynamics, rather than just engine power, enabled them to construct a machine that was not only capable of flying but also able to stay aloft with minimal energy consumption.
When it came to propulsion, they faced another challenge: existing engines were too heavy for their needs. Instead of waiting for external solutions, they collaborated with their mechanic, Charlie Taylor, to design and build a lightweight, custom internal combustion engine. They also designed and crafted their own propellers, treating them as rotating wings rather than simple boat-style blades, a massive innovation, which made their aircraft far more efficient than those of their rivals. This attention to detail and innovation in every component of their aircraft was another reason they succeeded where others failed.
Their relentless persistence, willingness to learn from failures, and disciplined engineering approach were essential to their breakthrough. Unlike many of their contemporaries, who sought fame, government funding, or public attention, the Wrights maintained secrecy, working in isolation to perfect their designs without distractions. They understood the importance of securing patents to protect their innovations before making their work public.
Combs argues that the Wright brothers’ success was not the result of a single invention but a systematic process of problem-solving, experimentation, and refinement. Their ability to analyze flight as a problem requiring control, rather than just power, was the key factor that led to the first sustained and controlled flight on December 17, 1903. This methodical, scientific approach laid the groundwork for modern aviation and remains one of the most remarkable achievements in engineering history.
From Theory to Flight: The Wright Brothers’ Consider the State of Their Work in 1901
In his 1901 lecture Some Aeronautical Experiments, Wilbur Wright presented the Wright brothers’ early research and challenges in achieving controlled, powered flight to the Western Society of Engineers. He began by analyzing the work of previous aviation pioneers such as Otto Lilienthal and Samuel Langley. While acknowledging their contributions, Wright pointed out discrepancies between their theoretical data and practical results, particularly in lift calculations. This critique demonstrated the Wrights’ commitment to empirical testing rather than relying solely on established but potentially flawed data.
To address these inconsistencies, the brothers conducted extensive wind tunnel experiments, testing over 200 airfoil shapes. This method allowed them to refine lift and drag calculations, leading to more reliable data than what was previously available. Their approach was notably rigorous, combining systematic experimentation with careful documentation. By using a controlled environment, they were able to isolate aerodynamic variables more effectively than previous researchers who relied solely on full-scale field tests.
Wright also discussed their practical glider tests at Kitty Hawk, North Carolina, where they encountered significant issues with stability, control, and lift efficiency. Unlike their predecessors, who focused primarily on achieving sufficient lift, the Wrights recognized that controlled flight required a holistic approach integrating stability and maneuverability. Their key innovation was a three-axis control system, incorporating wing-warping for roll, a movable rudder for yaw, and a forward-mounted elevator for pitch control. This breakthrough was instrumental in developing an aircraft that could be actively controlled in flight, rather than merely gliding passively.
Despite their progress, Wright acknowledged the challenges they still faced, particularly in predicting lift accurately and maintaining stability under varying wind conditions. However, their scientific approach—rooted in systematic experimentation, iterative design, and careful observation—set them apart from other aviation experimenters of the time. This methodical process ultimately led to their success in achieving powered flight just two years later in 1903. The lecture not only documented their technical findings but also highlighted the importance of a data-driven approach to engineering challenges, a principle that remains fundamental in modern aeronautical research.
This is an enlightening glimpse into the engineering mindset and technical methods the Wright Brothers’ were practicing in the moments that led up to the 1903 breakthrough of achieving powered controlled flight.
The Wright Brothers’ Risk Management Approach Contributed to Success
Now back to the risk management theme. Orville and Wilbur Wright were unique in that they had a keen sense of the need for safety in the development of the first aircraft capable of sustained, controlled flight. To understand why, you must first understand the context of the effort to develop such craft at the time. The state of science was confused and mostly inaccurate or just plain wrong. One of the leading experimenters of the time, German Otto Lilienthal, was killed in an experimental glider of his own design in August of 1896. During that flight the glider nosed down sharply from an altitude of approximately 15 meters and struck the ground with great force, breaking Lilienthal’s neck. Unfortunately, this is an example of one of the great impediments in the achievement of flight until the Wright Brothers’ achievement: to test your ideas and designs, you put your life at risk.
The Wright brothers were uniquely capable of managing the risks of early flight experimentation due to their systematic, scientific approach and deep mechanical expertise. Unlike many of their contemporaries, they prioritized control over raw power, recognizing that a safe, stable aircraft was key to sustained flight. Their extensive glider tests, conducted over several years, allowed them to refine their three-axis control system and gain invaluable piloting experience before attempting powered flight. To further mitigate risk, they intentionally kept their test flights at low altitudes, ensuring that any loss of control would result in minor crashes rather than catastrophic falls. This approach allowed them to make incremental adjustments without endangering their lives or severely damaging their aircraft. They meticulously analyzed aerodynamics using wind tunnel experiments, reducing uncertainties before building full-scale planes. Additionally, their background as bicycle mechanics gave them a practical understanding of lightweight structures, mechanical reliability, and incremental testing, enabling them to make small, controlled modifications rather than taking reckless leaps. By testing in the soft sand dunes of Kitty Hawk, they minimized injury risks, and by continuously learning from failures, they systematically improved safety and performance, ultimately achieving the first successful controlled flight in 1903.
A “happy accident” created another critical risk management principle for the aerospace industry. The Wright’s decision to place the vertical control surfaces (elevators) in the front of the wings, created a more stable aircraft regarding stall characteristics. Unlike conventional aircraft with tail-mounted elevators, which can enter an unrecoverable nose dive when stalled, the canard configuration of the Wright Flyer tended to pitch the nose back up automatically when the aircraft approached a stall. This made the aircraft more forgiving and increased pilot survivability in the event of a control loss. The Wrights realized that this characteristic, while not originally intended as a safety measure, helped them manage the risks of early flight testing by giving them an added margin of control. It also demonstrated the need to test a new design for its stall characteristics, a standard part of aircraft development for many years now.
Another aspect of risk management was the Wright brothers’ practice of intense debate over technical topics was a crucial factor in their scientific rigor and accuracy, shaping their methodical approach to solving the challenges of flight. Wilbur and Orville engaged in frequent, often heated discussions about aerodynamics, control mechanisms, and engineering principles, challenging each other’s assumptions and refining their ideas through logical argumentation. Their debates were not merely disagreements but structured discussions that forced them to defend their reasoning with data, calculations, and experimental results. This process helped them eliminate flawed theories and refine their designs with precision.
A key example of this dynamic was their debate over wing-warping and control surfaces. Through back-and-forth discussions, they refined their understanding of how an aircraft could maintain stability in three dimensions, leading to their groundbreaking three-axis control system. Similarly, their debates over lift and drag calculations drove them to conduct wind tunnel experiments rather than rely on outdated theoretical data from predecessors like Otto Lilienthal and Samuel Langley. By constantly questioning and challenging each other’s ideas, they ensured that their conclusions were based on empirical evidence rather than assumptions.
This rigorous analytical approach set them apart from many other aviation pioneers of their time, who often relied on intuition or incomplete theories. Their ability to engage in constructive technical debate and use of mathematical computation, combined with hands-on experimentation, allowed them to make incremental scientific principle-based improvements with confidence.
The Wrights’ Applied Risk Assessment Methods to Flight Experiments
The Wright brothers were pioneers not only in aviation but also in applying early risk assessment methods to ensure the safety of their experimental flight program. Unlike many of their contemporaries, who pursued powered flight through trial and error, the Wrights took a methodical approach to identifying, analyzing, and mitigating risks. Their strategy involved the use of unmanned gliders for initial design validation, then extensive wind tunnel testing, which allowed them to refine their understanding of aerodynamics and ensure their wing designs were efficient and stable before attempting full-scale manned flights. By conducting over 1,000 glider flights at low altitudes in the soft sand dunes of Kitty Hawk, they systematically reduced the risks associated with high-speed crashes, allowing for safer landings and controlled test environments.
One of their most significant contributions to risk assessment in aviation was their emphasis on controlled flight rather than simply achieving lift. They recognized that without a reliable means of controlling an aircraft in three dimensions—roll, pitch, and yaw—flight would be dangerous and impractical. Their patented three-axis control system directly addressed this issue, enabling pilots to maintain stability and recover from disturbances in flight. Additionally, they minimized structural failure risks by meticulously testing materials and reinforcing critical components, particularly after the 1908 crash that resulted in the death of Lieutenant Thomas Selfridge. In response to that incident, they improved the durability of their propellers, strengthened aircraft wiring, and adjusted their airframe design to enhance safety.
The Wrights also employed a staged testing process, moving from kites to gliders to powered aircraft in incremental steps. This structured progression allowed them to gather data, make adjustments, and reduce uncertainties at each phase, rather than risking a catastrophic failure by rushing into powered flight. Their careful assessment of environmental factors, such as wind conditions and terrain, further demonstrated their risk-aware mindset. By prioritizing safety, control, and systematic problem-solving, the Wright brothers effectively implemented early risk assessment principles, making them uniquely capable of achieving sustained, controlled flight while minimizing dangers to themselves and others.
The First Aviation Accident Investigation Brings Safety Improvements
On September 17, 1908, the Wright Flyer was involved in a tragic crash that resulted in the first fatality in powered flight history. Orville Wright was demonstrating the aircraft at Fort Myer, Virginia, as part of trials for a potential U.S. Army contract. His passenger, Lieutenant Thomas Selfridge, was an Army observer evaluating the aircraft’s military potential. During the flight, at an altitude of about 150 feet, one of the Flyer’s wooden propellers unexpectedly split, causing severe vibrations that led to the snapping of a guy wire. This disruption caused the aircraft to lose control, sending it into a nosedive. Orville attempted to regain stability, but the plane crashed hard into the ground. He suffered serious injuries, including broken ribs and a fractured leg, but he survived. Tragically, Lieutenant Selfridge sustained a fatal head injury and died later that evening, becoming the first person to die in a powered airplane crash. This accident underscored the dangers of early aviation and prompted the Wright brothers to improve their aircraft’s structural integrity and safety features in subsequent designs.
The U.S. Army conducted a report on the 1908 Wright Flyer crash that resulted in the fatality of Lieutenant Thomas Selfridge, authored by First Lieutenant Frank P. Lahm. The report concluded that the crash was caused by a mechanical failure, specifically the splitting of a propeller blade, which led to excessive vibrations that damaged the aircraft’s structure. The vibrations caused the collapse of a supporting guy wire, resulting in the loss of control, and the plane nosedived into the ground. The Army’s investigation also noted that despite the crash, the Wright brothers had demonstrated the stability and controllability of their aircraft, as the accident was attributed to mechanical failure rather than a design flaw. The report emphasized the need for further testing and improvements, particularly in strengthening the propeller and structural components, to ensure the reliability and safety of future flights. Pictures of this accident and a broken piece of the right propeller are on display at the U.S. Air Force museum in Dayton OH.
Following the 1908 crash, the Wright brothers made several critical safety improvements to their aircraft to enhance stability and reliability. They redesigned their wooden propellers using stronger materials and improved construction techniques to prevent fractures like the one that had caused the accident. To further reinforce their aircraft, they strengthened the airframe, making it more resilient to stress and reducing the likelihood of structural failure during flight. Recognizing the need for greater control and redundancy, they introduced dual control systems in later models, allowing both the pilot and a co-pilot to maneuver the aircraft if necessary. They also improved engine mounting to reduce vibrations and prevent mechanical failures that could compromise stability. Additionally, since a snapped wire had contributed to the crash, they reinforced control cables and guy wires to withstand greater tension and minimize the risk of breakage. To enhance landing safety, they upgraded the aircraft’s landing gear with better skids and shock absorption mechanisms, reducing impact forces upon touchdown. These refinements significantly improved the safety and reliability of Wright aircraft, enabling their continued success in both military and civilian aviation.
The Wright brothers obtained several patents related to their aircraft designs, some of which contributed to safety improvements by enhancing stability, control, and structural integrity. Key patents include:
U.S. Patent No. 821,393 (1906) – Three-Axis Control System
This foundational patent covered the Wrights’ system for controlling an aircraft in three axes: roll (wing-warping), pitch (forward elevator), and yaw (rudder). This system significantly improved flight stability and maneuverability, reducing the risk of crashes due to loss of control.U.S. Patent No. 1,075,533 (1913) – Improved Control Mechanisms
This patent introduced refinements to their control system, making adjustments smoother and more reliable. These improvements enhanced pilot control, reducing sudden or unintended movements that could lead to accidents.U.S. Patent No. 908,929 (1909) – Efficient Propeller Design
After the 1908 crash, the Wrights focused on improving propeller reliability. This patent covered their advanced propeller design, which increased efficiency and reduced the risk of mechanical failure, a crucial factor in preventing structural stress and crashes.U.S. Patent No. 1,084,930 (1914) – Automatic Stability System
This patent introduced concepts for automatic stability mechanisms, including ways to correct an aircraft’s balance without direct pilot input. This was an early step toward automated flight control, enhancing flight safety by reducing pilot workload.
While these patents primarily focused on flight control and efficiency, they indirectly contributed to aviation safety by making aircraft more stable, reliable, and easier to control. The principles laid out in their patents became foundational for future safety advancements in aviation.
Concluding Thoughts
The Wright brothers’ success in achieving controlled, sustained flight was largely due to their systematic approach to engineering and risk assessment. Unlike their contemporaries, they prioritized control over raw power, recognizing that stable flight required mastery of roll, pitch, and yaw. Through extensive wind tunnel testing and incremental glider experiments, they refined their aircraft design while minimizing risks. Their staged approach to flight testing, low-altitude trials, and improvements following accidents—such as reinforcing propellers and airframes after the 1908 crash—demonstrated a keen understanding of safety. Ultimately, their most significant achievement was not just inventing the airplane but pioneering the first structured risk assessment methods in aviation, ensuring that flight was not only possible but practical and safe.
Interesting Further Reading:
http://www.libraries.wright.edu/special/wrightbrothers/patents/
http://corescholar.libraries.wright.edu/special_ms1_photographs/1273/
LeadingEHS.com 