B-24 Liberator - Retribution from the skies

Welcome to this latest edition of our Workbench blog and all the news, updates and modelling exclusives from the fascinating world of Airfix.

With the frenetic activity of range launch week now behind us and hopefully with most Workbench readers having now had the opportunity to inspect the finer details of the 2024 model range for themselves, we can now turn our attention to following the development of our current crop of highly anticipated new models, as they negotiate the various stages on their way to eventual release. A privilege the Workbench team holds dear, the opportunity to follow new Airfix projects from inception right through to arriving in model shops everywhere, allows us to share several related updates with our readers, with new tooling subject matter clearly being particularly important content for us.

With that in mind and as this is our first 'traditional' edition of Workbench for 2024, we wanted to begin a new year of updates in spectacular fashion and thanks to our Senior Product Designer Christopher Joy, that's exactly what we're going to be doing. Taking our first look at one of the new tooling projects announced for this year, please join us as we introduce readers to the new 1/72nd scale Consolidated B-24H Liberator tooling, where we will be exclusively revealing details from the early development of this impressive new kit, illustrated throughout with a fascinating selection of design images taken straight from Chris' computer. Constructed around a recent interview we conducted with designer Chris, we will begin by looking at the history behind this mighty US heavy bomber and why it should be regarded as much more than just a support aircraft for the arguably more famous Boeing B-17 Flying Fortress. We will also be highlighting how from a modelling standpoint, the Liberator could hardly be more appealing as a build subject, even though it's inclusion in the range did present one or two challenges for its designer.

Please join us as we embark on another exciting year of Workbench updates by welcoming this American aviation classic in 1/72nd scale to the 2024 Airfix range. 

Will you build Flying Fortress bombers for us?

Although the B-24 Liberator may have started its life following an official request to build Flying Fortresses under licence for the USAAF, the bomber would go on to become America's most heavily produced aircraft of the Second World War.

Over the years, many historians have argued that Germany's failure to secure decisive strategic victories throughout the Second World War was a direct result of the Luftwaffe not having access to an effective long-range heavy bomber and whilst such a claim may be difficult to corroborate, it's certainly not a problem Allied air forces had to bear for too long. Although Britain entered WWII equipped with twin engined medium bombers, they were already hard at work developing larger, more capable aircraft to take the fight to the enemy. Across the Atlantic, the USAAF already had an impressive four engined 'Heavy' in service, with another at the advanced stages of development.

It's interesting to discover that when looking at the history behind the development of the Consolidated B-24 Liberator, the story actually begins with a US Army Air Force request for Consolidated to produce Boeing B-17 Flying Fortress bomber for them under licence back in 1938. With the clouds of war gathering ominously in Europe, US officials were convinced that advanced heavy bombers would be playing a significant role in any conflict and in the Flying Fortress, they had an aircraft which was just about as good as it gets.

Following a visit to the Boeing production facilities in Seattle, Consolidated officials went back to the USAAF with an audacious counter proposal to their licence manufacturing request. They informed them that they were happy to build their bombers, but wanted to produce one of their own design, a new aircraft which would be better than the current Flying Fortress. Intrigued by their confidence, the USAAF invited Consolidated to submit a design study in January 1939, however, as the proposed new aircraft promised to be faster, was able to carry a greater bomb load and would have greater range than the existing B-17, it was virtually assured of gaining a future production contract.

Taking design inspiration from the existing PBY Catalina flying boat Consolidated were already producing, the new bomber featured a deep fuselage and innovative bomb-bay doors, doors which resembled metal roller shutters and moved up the side of the fuselage when opened. This feature had the dual advantage of allowing the aircraft to be 'bombed up' more efficiently when the aircraft was on the ground, but was also more aerodynamically efficient when opened in flight.

The Liberator also featured an advanced shoulder mounted 'Davis Wing' which was highly efficient and endowed the Liberator with greater speed and range than the B-17 Flying Fortress. Relatively thick in profile, the wing was much narrower and longer than the one used on the B-17 and was set high on the fuselage of the new aircraft, similar to the configuration of the PBY Catalina, with the high positioning of the engines helping to protect them from foreign object damage whilst on the ground, even though servicing would be more difficult for mechanics at bomber stations around the world.

It all began with a scan. For an aircraft which occupies such a significant position in the history of aviation, it's quite surprising to learn that there are just thirteen complete examples preserved around the world today.

A design screenshot from much later in the design phase of this new model, the scan data was crucial in allowing Chris to check all his shape and dimension data for this most famous of WWII aircraft.

The Liberator used four supercharged Pratt & Whitney R-1830-35 Twin Wasp engines housed in similar nacelles to those employed on the Catalina, even though the requirement to install oil coolers on either side of each engine gave the Liberator's nacelles a distinctly oval appearance.

During the B-24's flight testing programme, the aircraft posted performance figures which eclipsed those of the Flying Fortress, and highlighted the fact that it was indeed able to fly faster, carry greater bomb loads and over greater distances than its famous Boeing predecessor. Officials must have been excited at the prospect of introducing their advanced new bomber, particularly as the cavernous fuselage of the aircraft arguably made it a significantly more versatile aircraft than the Flying Fortress - the future certainly looked bright for America's new B-24 Liberator.  

Impressive as the new bomber undoubtedly was, it wasn't all good news for the new Liberator, as its advanced design presented several significant challenges for the service pilot flying it following its introduction. Certainly during the early years of B-24 operation, even the most ardent of B-24 supporters would have to concede that it was quite a challenging aeroplane to fly, heavy on the controls and with the high, narrow wing making it difficult to maintain position in the air at times. The aircraft had a tendency to wallow in flight and required almost constant corrective flight control inputs to be made by the pilot, which could be exhausting on a long mission. It has been reported many times that B-24 pilots and co-pilots would share flying responsibilities in twenty minute shifts between the two of them on long missions, just to keep themselves fresh and to avoid the potential of becoming overly fatigued. 

Consolidated's bomber becomes an aviation record breaker

This difficulty keeping the aircraft straight and level was claimed to have prevented B-24 groups from holding tight formation during raids deep into enemy occupied Europe, where the integrity of the formations were vital in ensuring the most effective mutual defence against attacking enemy fighters. Loose formations presented many more attack opportunities than one where many hundreds of defensive machine guns could be brought to bear in any direction.

Another fascinating image from the very start of this new tooling project, this time showing the scan data obtained of the underside of the mighty Liberator.

Once America's heavy bomber duo were committed to combat in large numbers, a great rivalry commenced between crews operating the aircraft, which each claiming theirs was the more effective combat aircraft. B-24 Liberator crews claimed that whilst their aircraft was more challenging to fly, it was a real pilots aircraft and could reach targets the B-17 simply didn't have the range to attack. Flying Fortress pilots described the B-24 Liberator as being nothing more than the box in which a B-17 was delivered and whilst the Flying Fortress was undoubtedly the more famous of the two aircraft, the Liberator was crucial to the Allied war effort and went on to become an aviation record setter.

A situation which really does highlight how the B-24 Liberator is positioned historically in the minds of many people occurred in February 1943, when B-24 41-23728 'Hot Stuff' of the 330th BS completed twenty five operational missions over Europe, the first USAAF heavy bomber to do so and a full three and a half months before the much more famous B-17 'Memphis Belle', the story of which we all know. 

After 'Hot Stuff' had completed 31 missions, it was decided that she and her crew should fly back to the US to undertake a war bond tour, however, during the subsequent flight home, the aircraft was lost during bad weather over Iceland, tragically claiming the lives of all but one on board. Due to the tragic nature of the incident, the USAAF decided to change their original plan and instead focus on the impending 25 mission achievement of the 'Memphis Belle', and the rest, as they say, is aviation history.       

Perhaps the most significant operational difference between the B-17 and the Liberator was how the design of the B-24 dictated that the aircraft was forced to operate at markedly lower altitudes than its Boeing comrade in arms, where they were vulnerable to more enemy aircraft and where flak defences were significantly more effective. As a consequence, B-24 Liberator crews suffered terribly at the hands of Germany's raid defences, even though they did deliver more bombs on target than any other Allied bomber type during WWII.

Made available to the British via the Lend-Lease Act, the impressive range and versatility of the Liberator saw these first aircraft to see combat during WWII pressed into service initially as trans-Atlantic ferry aircraft, taking delivery pilots to the US to pick up new aircraft to fly back to Britain. Others performed the vital role of airborne anti-U-Boat protectors for naval convoys during the Battle of the Atlantic, a battle which for Britain at least, was the most critical of the entire war. 

As this box artwork image has already broken cover, we thought it appropriate to show it once again within this project design introduction.

Following its subsequent USAAF introduction in 1941, the B-24 Liberator would go on be produced in vast quantities, serving in every theatre of war during WWII, and making a vital contribution to the Allied War effort. Indeed, it could be argued that no other aircraft came to represent the incredible industrial might of the American war machine than the B-24 Liberator, an aircraft which during its production life, was manufactured at five different plants across the country. It was claimed that at its height, the Ford production plant at Willow Run Michigan could construct Liberators faster that the USAAF could process them into service, with some sources claiming around one bomber per hour could be produced by teams at this impressive facility.

The introduction of the 'H' model addressed the aircraft's vulnerability to frontal attack once and for all, something enemy fighter pilots had been exploiting since the B-24's combat introduction. This variant was the first to be manufactured from the outset complete with an electrically operated Emerson A-15 nose turret, in addition to introducing around fifty other design modifications to make the Liberator a more combat effective aircraft. Although earlier versions of the Liberator did feature nose turrets, they were introduced later in the production run of those variants and even in some cases, installed as in-service modifications. 

With just under 18,500 machines produced, the Consolidated B-24 Liberator would go on to become the most heavily produced four engined bomber in the history of warfare and America's most produced aircraft of the Second World War. Quite simply, the B-24 was flown by more men, carried more bombs over greater distances and destroyed more targets than any other bomber in the history of aviation - quite impressive numbers for an aircraft which is probably still in the shadow of the Flying Fortress. 

The scale honouring of an aviation classic

For modelling enthusiasts, there is something really appealing about building a large WWII bomber kit, with all that interesting detail and a host of interesting sub-assembly sections to tackle.

Although we in the modelling community continue to be fascinated by the skills possessed by the Airfix design team and how they are expert in turning some of history's most important machines into scale model kits, for them, the actual design process can be quite similar for them, no matter what subject they are tackling. That's not to say they don't each have their own particular favourite subjects to work on, or that they don't enjoy the thrill of a new design challenge, it's just that the design process as a whole usually follows something of a familiar pathway. This can even be the case when tackling projects in different scales, even though detail levels and thickness tolerances will clearly alter as the scale of a model project increases.

For a designer with as much experience as our own Christopher Joy now has to his name, we suspect that he has few concerns, if any, in advance of learning the subject of his latest design project, as there can be few design challenges he hasn't faced and overcome over the years. Nevertheless, Chris himself will be the first to explain how the learning of new skills is a continual process and how each design project brings its own set of challenges and associated achievements.

With such impressive recent design achievements behind him as our 1/24th scale Spitfire Mk.IX and the Westland Sea King in 1/48th scale, we were keen to find out how the new 1/72nd scale B-24 Liberator project compared to these high profile additions to the Airfix range and from a designers perspective, if it posed him any particular challenges. We were also interested to find out if working in all these differing scales in a relatively short period caused him any issues from a design perspective.

Taking the last point first, Chris informed us that from a scaling perspective, there can be some quite significant differences when working in different scales and without question, a 1/24th scale project is both more challenging and much more time consuming than if the same subject were to be designed in a smaller scale. The additional levels of detail which need to be incorporated into the design of a larger scale kit can often be significantly more challenging and definitely requires some previous design experience to negotiate successfully, however, no matter how much experience a designer might have to their name, a 1/24th scale project is still going to take them many months to complete.

Turning his attention to the new B-24 Liberator, Chris described how he always finds it exciting when embarking on a new design project and how some variety in subject matter can always be both enjoyable and rewarding. For this project, Chris was particularly keen to get started on the B-24 because he had prior design experience with a four engined USAAF heavy bomber in this scale, as he also designed the Boeing B-17G Flying Fortress which was first released back in 2016. He knew there would be many design similarities between the two projects, but was interested to see how many differences there actually were between these two great aircraft.

This fascinating early project image shows the original scan data of the B-24 Liberator overlaid on top of Chris' design files, a valuable tool in checking detail placement and shape data. 

Chris' project brief for the new Liberator included scan data from a preserved example of this most heavily produced American aircraft of WWII, in addition to an array of supporting research and variant option information, essentially everything he needed to get started on his latest project. With his previous experience designing the Boeing B-17 kit, he already had a good idea how the design phase itself would be split and indeed, how he intended to proceed throughout the project.

The challenge facing a designer when working on an aircraft of this size, but in this scale, is the need to include detail at the appropriate levels, not so much that it just looks odd, or indeed, not so little that everything gets a little lost. This might sound like common sense, however, from a designers perspective, can be incredibly difficult to do and requires every ounce of experience they possess, not just design skill, but also a good understanding of the tooling design and manufacturing process, and the eventual production process for kit manufacture. All these factors need to be taken into consideration if the required level of internal and external detail is to be accurately represented in the design of the new kit they are working on.

In a similar way to how he recalls designing the Boeing B-17 Flying Fortress kit, Chris knew that the best way to approach a large WWII bomber was to do it in sections of design, breaking it down into little sub-projects within the fuselage, including cockpit, bomb bay detail and the various defensive gun positions. For Chris, this really did make it seem as if he was working on a series of smaller, yet connected design projects, which whilst clearly all coming together later, added both interest and variety to the task whilst he was working on them. 

Chris described how he found it particularly interesting to discover how the space within the bomber all connected together and how the crew were able move about inside the aircraft during operations. He said, "At the end of the day, we're in the business of designing a scale representation of one of the most famous aircraft types of the Second World War, one which was flown by real people, very brave people who all had their own stories to tell." Chris just wanted to tell his own design story well and create a fitting scale tribute to the B-24.

Another scan overlay design screenshot which is 100% B-24 Liberator. It also highlights just how much Chris still has to do on this significant design challenge.

With regard to the design project itself, Chris' work on the earlier B-17 Flying Fortress certainly helped when it came to producing his project roadmap for the B-24 and actually allowed him to use an almost identical set of design files for the lower fuselage ball turret, which is a feature of both kits. He also knew which sections of the B-24's interior would be needing his attentions when it came to adding appropriate levels of detail and what might be viewable once the kit had been assembled.

Having briefly touched on the subject of internal detail, we wanted to explore this a little further and asked Chris for his thoughts on the inclusion of internal detail for a kit in this scale?

A subject which can be the cause of much passionate discussion within the modelling community and something which is invariably a topic of many a conversation o be heard around the Airfix stand at Scale ModelWorld each year, it's clear that internal detail incorporated into the latest kit designs delights some modellers, whilst frustrating others. Some love the fact that all that beautiful detail is there and how it enhances their overall build experience, whilst other think it a waste of time and effort, as you struggle to see much of it once the kit has been assembled.

An image which will be comfortably familiar to all our designers, but one which blows the minds of modelling enthusiasts. How on earth do Airfix designers go from this to a successful scale model kit release?

As you can see, there really isn't a definitive answer to this particular question, but as far as Chris is concerned, he understands how lots of people do like the inclusion of internal detail, particularly in kits such as the Vickers Wellington and this new B-24 Liberator, so he does like to incorporate it into his designs when it's appropriate to do so. General rules of practicality are the order of the day here though, because if a modeller can see the detail, such as in the open bomb bay, through one of the gun ports or within one of the four gun turrets, then this is fine and must be considered. On the flip side however, if it would be difficult or impossible to see that detail once the kit has been assembled, then that really is something of a futile exercise. It all comes down to a question of a designer's time and the cost associated with such effort, when it comes to the inclusion of internal detail.

3D printer technology is the friend of the Airfix designer

With regard to the B-24, Chris actually spent quite some time incorporating internal detail into the kit's design and he hopes this will add much to the overall build experience of the kit once people start working with it. Areas around the open waist gun positions include detail such as ammunition boxes, lots of internal fuselage structure and the brightly coloured oxygen bottles crews relied on during operations, in addition to the inclusion of the more usual cockpit and bomb bay detailing.

We're probably in danger of getting slightly ahead of ourselves here, however, this next selection of images really do illustrate the issue of design internal detail perfectly. We begin with a design sectional screenshot featuring the starboard fuselage half of the new B-24 Liberator, with this selection of images ending with an incredibly appealing painted model interior image, produced during a project test build.

Can we please ask what design challenges, if any, you faced whilst working on the new B-24 Liberator kit?

Chris told us that in almost every case, each new project will throw up a design head-scratcher or two, but how in most cases, there are usually several different ways in which to overcome any problem, the clever bit is choosing which is the right one. On the B-24 Liberator project, he recalls the various turret designs as being particularly challenging design features, albeit a challenge he really enjoyed tackling. 

All four turrets are of a different design, but each one requires the extensive use of clear components, parts which obviously allow quite an amount of internal detail to be seen. The design challenge here is to replicate this detail as accurately as possible, whilst at the same time working around the part thickness parameters a kit in this scale must conform to, and without over-complicating the assembly process.

When it comes to fine detail, there is no point including a part that's so thin that it either won't mould correctly, or will break on its frame the second it has even the slightest amount of force applied to it. In addition to this, a huge collection of tiny parts concentrated in any assembly stage is a bad thing and wherever possible, combining several small parts into a more robust, yet still detailed component is definitely the preferable design option to take. Chris informed us that he's really pleased with how this aspect of the kit's design turned out and when assembled, the new Liberator really does look ready for action.

Other B-24 design challenges included the accurate representation of the bomber's distinctive 'roller shutter' style bomb bay doors and how these follow the shape of the fuselage if modelled in the open position, along with how the model will always try to sit on its tail, if remedial actions are not taken. On the real aircraft, the weight of the four Pratt & Whitney Twin Wasp engines would have helped to keep the bomber's nosewheel on the ground, but as we are working in plastic, we had no such help.

To help overcome this, Chris incorporated a couple of hidden compartments in the forward fuselage where weight can be added and doesn't run the risk of becoming loose and rattling about inside the model. If all else fails, the inclusion of a rear fuselage crew ladder will keep the Liberator kit in the correct attitude, should you decide to finish your model in airfield configuration.

Another fascinating selection of exclusive design images to share with Workbench readers, starting with a visual indication of how Chris built up the internal detail in the nose section of the Liberator's nose. We move on to look at a screenshot showing how Chris replicated the bomber's distinctive bomb bay doors, before moving on to look at the very different front and rear gun turrets.

Another extremely challenging aspect of the B-24 kit's design were its wings and how Chris managed to accurately represent the 'Davis Wing' which was such a distinctive feature of Consolidated's record breaking bomber's design. Clearly longer and narrower than the wing used on the Flying Fortress, the Davis high performance wing is actually quite thick and in order to ensure they retained their shape integrity during the assembly process, Chris needed to introduce support formers into his design and working closely with our illustrator, ensure clear guidance was provided to the modeller for when they were tackling this section of the build.

These were just some of the design challenges Chris remembers being quite pleased to be able to move on from, but is nevertheless pleased with how they turned out on the kit itself. On the positive side, the unusual wing design of the Liberator meant that he didn't have to design any wing fillets, something which is shape critical and can actually take some time to figure out, so in design terms, this was definitely a win-win situation. 

As we all look forward to welcoming the new Consolidated B-24H Liberator kit to the 2024 Airfix range, we wanted to ask Chris if he remembers anything about the design phase as being particularly memorable for him, and were rather surprised by his answer. 

Chris told us that the use of the in-house Airfix 3D printer proved both useful and enjoyable throughout this project, not only because it allowed him the ability to further hone his 3D printing skills, but also because it gave him the opportunity to check several sections of the design for detail and assembly accuracy before moving on to the next stage. Providing the opportunity to answer any design queries as they presented themselves, having access to the 3D printer allowed him to check and overcome any issues as he progressed through the project, rather than them only coming to light during the tooling layout and initial frame checking phase of development, something which proved a real time (and money) saver.

Chris made full use of this option whilst designing each of the B-24's turrets and in each case, set the printer running just before he left for the day, knowing he would have a nice 3D printed surprize waiting for him when he arrived back in the morning.

Although our 3D printer is a good one, it doesn’t have the capability to produce a full new tooling prototype print, but is more than capable of producing parts to allow smaller sections of any current design project to replicated and is used extensively for this purpose by all our designers. Before it can be printed, the design components in question have to be converted to the STL format the printer can recognise and whilst the printing process can take many hours to complete, most of these printing tasks take place during the evening and through the night, for maximum efficiency.

Having access to a quality 3D printer 'in-house' allows the design team the opportunity to check smaller sections of the design project they are working on at the point of concern, saving time and money, whilst at the same time making sure everything remains on schedule.

Unfortunately, some of the surprises the 3D printer creates are not always as intended and the resultant parts can sometimes look nothing like as expected. this could be because the previous user of the equipment didn't clean it properly, or that there might have been something stuck in the printing head, or some contamination or other and whilst you might be expecting a selection of turret pieces, you might end up with something which is a bit of a disappointment.

Other issues such as software incompatibilities, or a file which doesn't include enough, or correctly positioned supports can also cause print failures, however, around 80% of the time, everything works as intended and design components can be checked and if required, modified.

Once the 3D printed parts have been created, they need to go through a further process of hardening, so they're rigid enough to be worked with and once finally cleaned up, can be assembled and used to check the aspect of a new tooling design the designer was concerned about. Our printer technology is great for replicating relatively small components, but for something as large as the fuselage half of a B-24 Liberator, it wouldn't be able to handle this without running the risk of the part warping, or even completely deforming during a very lengthy print session. We still elect to have the full prototyping of a new model tooling design handled by a trusted professional prototyping company, however, access to in-house 3D printing technology is an important resource available to the Airfix design team and is something they all make use of regularly.

A significant new addition to the Airfix range

In summary, Chris told us that he really enjoyed working on the B-24 Liberator project and particularly how designing the interior detail featured on the kit allowed him to understand more clearly where all the individual crew positions were, how much space they had to work in and if necessary, how they navigated their way through the mighty bomber whilst it was being used operationally. He thinks he has managed to include plenty of detail into his new design, both inside and out, and how he hopes modellers will enjoy their time spent building the new B-24 Liberator once it eventually lands on their workbenches.

This penultimate selection of images begins by showing the high set 'Davis Wing' and how Chris managed to replicate this in design.

From a blog update perspective, we have to remember that when a new tooling project such as this one comes to our attention, it's usually at an advanced stage of development and the designer we're questioning will have more than likely long since moved on to another project, or may even have a couple of new (still secret) designs to their name. With that being the case, we hope Chris didn't mind being dragged back to a world of bomb bays and defensive turrets too much.

To end our time with Chris, we couldn't let him go without asking the million dollar question, even though it was rather a predictable one. With both of America's main four engined heavy bombers of the Second World War now in his 1/72nd scale Airfix design portfolio, we wanted to know which one he enjoyed working on most?

In a diplomatic fashion which clearly hints at a future career in politics for Chris, he remained firmly on the fence and told us that both were equally rewarding from a design perspective and how both include really interesting design features to be replicated in scale. For him, even though the overall shape of each aircraft is the thing that continues to captivate modellers and enthusiasts, the ability to see the internal layout of both aircraft is the most interesting aspect of each kit's design and how the two companies approached the same aviation task in quite different ways.

He did end by saying how he feels incredibly fortunate to have both these magnificent aircraft on his Airfix design C.V, particularly bearing in mind the significant position both bombers hold in the history of aviation.

We would like to thank Chris for allowing us this insight into his design world and for guiding us through the work he did in bringing this magnificent new 1/72nd scale representation of the Consolidated B-24H Liberator to the 2024 Airfix range. We are particularly grateful for the fabulous selection of images he furnished us with, and how each one helps to illustrate the design points raised during our interview.

This final selection of images feature a design screenshot image showing internal Liberator detail, a computer rendered image produced from those files which is used for marketing purposes and finally, an image showing a test build section of the impressive new 1/72nd scale Consolidated B-24H Liberator kit.

We look forward to posting the next instalment of B-24 Liberator developments, as this impressive new model kit speeds its way towards eventual release.

We are afraid that's all we have for you in this latest edition, but we will be back next Friday with more project development updates and the very latest Airfix kit exclusives. In the meantime, we are always keen to hear your views on all things Airfix and in particular, any thoughts and opinions you may have regarding our Workbench blog. If you would like to drop us a quick line, could we please ask that you use our workbench@airfix.com email for all correspondence. 

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