Flight Structures News

Helicopter Performance STC gained for Northland Emergency Services Trust

Mon, 10 Dec 2018 00:00:00 +1300

Flight Structures has recently been successful in helping Northland Emergency Services Trust gain an STC for their new Sikorsky S76.

This is the cover photo featuring the S76 in action in Whangarei.

We thank NEST for their support during this project as well as John King for the fantastic cover photo.

Here is a link to the PDF Article and you can buy NZ Aviation News at all good local newstands.

FSL in the news: Air Ambulance on Cover of NZ Aviation News

Thu, 07 Dec 2017 00:00:00 +1300

Flight Structures is proud to be one of the organisations involved with the refit of the Westpac Air Ambulance. For details of the project please purchase your copy of NZ Aviation News at your local newsagent or via this link

Aviation News

FSL team in BNZ Corporate Challenge at the Avantidrome

Mon, 25 Sep 2017 00:00:00 +1300

Flight Structures is fortunate to be based close to the Avantidrome, which is a world class velodrome on the outskirts of Cambridge. Jon, Clyde and Brett are all regulars at the velodrome, so this year we decided to enter a team in the BNZ Corporate Challenge which was held over the past two weekends. As they are experienced riders, they completed in the Open Men's section of the Cambridge Pursuit. After six races, both time trials and against other teams, the FSL team ended up in 6th place.

The Cambridge Challenge consists of a three person team racing over six laps, or 1500m. All three riders complete two laps, then the front rider peels off, the second rider then leads for another two laps,with the final rider completing the last two laps on their own.

Stretcher Loading System for Mu-2 Air Ambulance

Thu, 24 Aug 2017 00:00:00 +1200

Flight Structures, in conjunction with Philips Search and Rescue Trust has developed a stretcher loading system for the MU-2 Westpac Air Ambulance. Here is a video demonstrating the system in action.

Click here for EMS System in action

The key features of this product include the following :

There is no lifting required from paramedics or pilots.
The secure smooth loading system leads to reduced patient stress.
The system has the ability to handle bariatric patients.
Patient loading onto the aircraft is quick, less than two minutes from beginning to end.
STC Approved under the CAANZ.

In operation for over six months now, Philips Search and Rescue Trust are very happy with the performance of the system.

Still more Supplemental Type Certificates Achieved

Tue, 13 Jun 2017 00:00:00 +1200

It has been a busy start to the year for the Flight Structures team with several new Supplemental Type Certificates Approvals being achieved over the last six months. This brings us to a total of 34 STCs as of June 2017. Please refer to this link to a full list.

You can contact us if you are interested in any of these approvals. We can provide more information for you.

Watch out for new stories with more details about some of these approvals.

FSL in the News: From Concept to Creation

Thu, 08 Dec 2016 00:00:00 +1300

Flight Structures featured in Kiwiflyer late last year with an article about the full range of services that we offer. Please refer to page 49 (page 25/33 of the attached edition.

Kiwiflyer Article

Supplementary Type Certificate List updated

Wed, 26 Oct 2016 00:00:00 +1300

We have been doing some housekeeping and maintenance of our website to encapsulate the breadth of services that Flight Structures offers. As part of this we have updated the list of STC's that we have either assisted our clients with, or that we hold ourselves.

You can find the list by clicking on this link STC Approval List

We've also refreshed the products section of the aircraft. This can be reached via this link Updated products page

Helisika successful with Bike Rack STC

Wed, 29 Jun 2016 00:00:00 +1200

Flight Structures has been successful in gaining an STC (Supplemental Type Certificate) for Helisika. The new bicycle racks fit onto AS350 helicopters for adventure tourism clients. This STC allows bicycle racks to be placed on the left hand or both skids of the rotorcraft, allowing up to six bikes to be carried by the helicopter.

Chris Raynes, Senior Certification Engineer commented “The bike rack design is very effective, using a simple method to secure the bicycles to individual troughs. The bicycles can be quickly loaded/unloaded from the helicopter clear of the cabin doors speeding up turnaround times.”

For more information about heli-biking or Helisika please refer to their website www.helisika.co.nz

FAA STC for R66 Spray System

Thu, 09 Jun 2016 00:00:00 +1200

Flight Structures has worked with Airlift Technologies to successfully gain a Supplemental Type Certificate (STC) for a spray system for R66 Helicopters.

What is a STC? A Type Certificate (TC) is issued when an applicant has received FAA approval to modify an aeronautical product from its original design. The STC, which incorporates by reference the related TC, approves not only the modification but also how that modification affects the original design, (from FAA Website)

Flight Structures also worked with Airlift Technologies to gain a NZCAA STC. Please click here for our previous news item for more information.

R66 Spray System Certification

Thu, 14 Apr 2016 00:00:00 +1200

Flight Structures Ltd has recently certified the re-design of a spray system for the Robinson R66 turbine rotorcraft.

Originally certified in 2012 for use in slurry delivery, the new system has been optimized for sale as conventional spray application equipment by Airlift Technologies Ltd

Due to the recently signed bilateral agreement between NZCAA and the FAA, this system is now available for purchase by operators in the US and other FAA aligned countries.

For enquiries contact airlifttechnologies.nz@gmail.com

Sora Fuselage Completed

Mon, 15 Feb 2016 00:00:00 +1300

Flight Structures team has been progressing the Sora project, and Stage One is now complete. Some photos were taken to demonstrate the spaciousness an aircraft of this size and shape offers. We have mocked up several other scenarios including LDF containers, passenger and club seating arrangements to provide clear visuals.

If you want to see further photos please refer to the Sora Aircraft Blog.

Nose cones for Westpac Rescue-Auckland

Thu, 04 Feb 2016 00:00:00 +1300

Flight Structures fitted two weatherproof nose cones to Westpac Rescue – Auckland for ZK-HLN & ZK-HKZ, their BK117-850 D2 Helicopters. Rescue aircraft have to work in a wide variety of conditions, and this modification ensures cockpit avionics remain dry. The modified profile accommodates the weather radar. Jon Kerr, CEO of Flight Structures commented, “We managed to supply the nose cones within a tight timeline, and worked effectively with the crew to ensure a successful installation. The end result was excellent, and the Trust are extremely happy with the performance of the nose cones."

Attached are some photos of the aircraft both in service and in the hangar.

The Auckland based Westpac Rescue Helicopter is staffed full-time by a highly experienced flight crew consisting of pilots, paramedics and crewmen, and operates 24 hours a day, 7 days a week, 365 days a year. Here is a link to their website.

Westpac Rescue-Auckland

Sora Project underway

Tue, 22 Sep 2015 00:00:00 +1200

Seed funding has allowed construction to progress on the Sora Aircraft fuselage. The blog is being updated regularly with new photos and information. This picture shows some of the team that have been involved with this project.

The website and blog can be found at www.soraaircraft.com

Mid Year News

Thu, 25 Jun 2015 00:00:00 +1200

The Flight Structures team has been hard at work over recent months on a number of projects for aero-medical, agricultural and charter aircraft.

We have also added a new engineer to our team, Isabel Bird, who replaces Bevan Small who left us on an overseas adventure.

Over recent weeks the Flight Structures website has been progressively updated, to include details of our products that are available as Major Modification or STC.

As a couple of these major projects come to conclusion, we look forward to sharing their details here.

Helicopter Medical Refit complete.

Tue, 21 Apr 2015 00:00:00 +1200

Flight Structures have completed the internal refit of a BK117 for emergency medical services (EMS).

The refit consisted of the installation of a Stryker stretcher and two triple seats, medical oxygen system, and an avionics shelf. The Flight Structures cabin seats were designed to be comfortable and provide clear space under the seat base for stowage of equipment. Using space effectively is all important for EMS helicopters.

Other modifications installed include a new tail antenna mount, external LED lighting, a zoll monitor mount, a nose cone to accomodate radar and snow shoes.

Flight Structures CEO Jon Kerr states "This was a long and complex project; we had a restrictions in space, weight, timeframe and budget to juggle. The end result is a great aircraft for the operator, Philips Search and Rescue Trust, and for the Palmerston North and Whanganui region where it will be based."

Partnering organisations with the refit were The Clevedon Aeroplane Company, Pacific Aero Coatings, Rotorcraft, Matcraft, Hamilton Aero Avionics, and TechAir.

Please see our Products section for more details about the Flight Structures modifications.

Shown in the pictures is the Stryker Stretcher system, the 6 person Cabin seating, and Flight Structures Chief Draughtsman Clyde James with ZK IPT.

Here is a link to an Engineering News Article about the refit of IPT.

Engineering News Article

Here is a link to a Philips Search and Rescue Trust Article about IPT

PSRT Website

Garden City Helicopters head to Vanuatu for Cyclone Relief

Fri, 27 Mar 2015 00:00:00 +1300

Garden City Helicopters, based in Christchurch, has sent two helicopters to Vanuatu for disaster relief, after Cyclone Pam caused widespread destruction on the islands. These aircraft will be used to deliver aid, assist with medical evacuations and repairing telecommunications. Garden City already has a subsidiary company in Vanuatu, Vanuatu Helicopters, who operate an R44 and an R66.

Flight Structures was involved in the certification of the ferry fuel systems (a ferry fuel system involves an auxiliary tank being added to the aircraft to extend the range) to get the AS350 and BK117 to the islands. Chris Raynes flew to Christchurch to be on site for the install with Henry Dumbleton being based in our office, both working with the CAA to ensure a very quick turnaround.

Here are some links for more information:

News article from Stuff including video footage. Click here

Another news article from Scoop. Click here

A link to the Garden City Helicopters website Click here

Aero Medical Refit Nearing Completion

Wed, 25 Feb 2015 00:00:00 +1300

Flight Structures has spent the last few months working on a major project refurbishing of a BK 117B-2 for Philips Search and Rescue Trust. This aero medical refit is almost at completion now. It has been a busy time for both our manufacturing and consulting divisions.

More to come in a couple of weeks with some photos to share.

Engineering Intern Programme at Flight Structures

Tue, 17 Feb 2015 00:00:00 +1300

This summer Flight Structures employed three interns to provide work experience for Mechanical Engineering students who are about to enter their final year of study.

This is the fifth year Flight Structures has taken on summer interns. We had a very high calibre of applicant this summer and ended up employing three, two from Canterbury University, and one from Auckland University.

Our intern programme is mutually beneficial. It provides experience in both practical and professional work for the students, and it keeps Flight Structures management in touch with the needs of current graduates. We are able to utilise their skills working alongside our senior experienced staff.

As most of our staff attended university in New Zealand it is also an opportunity for us to give back to the profession.

FSL in the news: Waikato Times December 5th

Wed, 10 Dec 2014 00:00:00 +1300

Flight Structures was featured in the "Waikato Means Business" supplement in the Waikato Times, 5th December. In this article by Jamie Small, you can see a more light hearted view of the FSL office. The article also details some of the benefits of like minded businesses working in close proximity to each other.

Click on the following link to read the article.

Cluster makes Collaboration easy

Flight Testing in Gore

Fri, 07 Nov 2014 00:00:00 +1300

Flight Structures Design Delegate and Senior Engineer Murray McGregor was invited to be involved with the Transport Accident Commission investigation into the Fox Glacier accident. Below is the article from the Gore Ensign on Wednesday November 5th.

Phoenix Aviation at Charlton is the base for a partial review of evidence relating to the 2010 crash of a Walter Fletcher aeroplane at Fox Glacier. MARGARET PHILLIPS reports.

Phoenix Aviation, at Charlton airport, is being used by the Transport Accident Investigation Commission to carry out a partial review of evidence that led to its findings regarding the 2010 crash of a Walter Fletcher aeroplane at the Fox Glacier aerodrome.

On September 4, 2010, the pilot of the plane, with eight parachutists on board, lost control during take›off from Fox Glacier aerodrome. The aeroplane crashed in a paddock adjacent to the runway, killing all nine occupants.

Commission deputy chief investigator Peter Williams, of Wellington, said the partial review of evidence was carried out at Phoenix Aviation earlier this week as the southern venue was the most suitable. Phoenix Aviation had a Walter Fletcher aircraft. The review was prompted by questions raised at the inquest, Mr Williams said. ‘‘It’s part of a number of aspects of inquiry that we’re reviewing,’’ he said. The review had been carried out this year.

‘‘There’s a lot of things to be looked at.’’

Flight Structures consultant Murray McGregor, of Hamilton, also travelled to Gore to help with the review. Mr McGregor said the object of the visit to Phoenix Aviation was to generate basic data on the flight characteristics of the Walter Fletcher. The Walter Fletcher was predominantly used as a topdressing plane, he said. The Transport Accident Investigation Commission’s findings on the accident said there were no technical defects identified that might have contributed to the accident and the aeroplane was considered controllable during the take-off roll, with the engine able to deliver power during the short flight. ‘‘The aeroplane’s centre of gravity was at least 0.122m rear of the maximum permissible limit, which created a tendency for the nose to pitch up,’’ the findings stated.

‘‘The most likely reason for the crash was the aeroplane being excessively out of balance. In addition, the aeroplane probably became airborne early and at too low an airspeed to prevent uncontrollable nose›up pitch.’’ The aeroplane reached a pitch angle that would have made it highly improbable for the unrestrained parachutists to prevent themselves sliding back towards the tail, and any shift in weight rearward would have made the aeroplane more unstable.

Photograph : Flight Structures consultant Murray McGregor (left), of Hamilton, and Transport Accident Investigation Commission deputy chief investigator Peter Williams, of Wellington, wait for a break in the weather at Charlton airport during their review of evidence relating to the 2010 crash of a Walter Fletcher aeroplane at Fox Glacier. PHOTO: MARGARET PHILLIPS

Manufacturing Approval Gained

Fri, 09 May 2014 00:00:00 +1200

On May 8th 2014 Flight Structures gained Part 148 status for it's Hamilton Aeronautical workshop facility. Derek Lewis, Workshop Manager explains, 'Part 148 approval enables Flight Structures to release certified parts and products with a Form One certificate which assures quality and greatly simplifies product embodiment for our clients.'

Jon Kerr, CEO stated 'This is a wonderful milestone for Flight Structures, and the culmination of a lot of hard work by our staff. The manufacturing facility has been busy over the last year, with recent projects including hi-tech flexible snow shoes and an aeromedical cabin fit-out. Combined with Part 146 Design Organisation approval Flight Structures is ideally set up for rapid prototype and design-build projects where customer requirements come first.'

Flight Structures is continuing to expand our capabilities and will be adding to our product list over the coming months.

STC gained for modification of 750XL flap system.

Thu, 03 Apr 2014 00:00:00 +1300

Farmers Air, one of New Zealand’s leading agricultural aircraft operators, came to Flight Structures to design a new flap system for their PAL 750XL aircraft. The standard flap actuation system is electrically actuated contained under the cabin floor, which is practical for utility aircraft. However this was proving to be mechanically unreliable due to the high cycle nature of agricultural operations and maintenance intensive.

Flight Structures redesigned the flap system to be located above the cabin floor and hydraulically actuated. The flap system and hydraulic components were sourced locally in Hamilton.

Flight Structures was responsible for the design and certification of the hydraulic flap system. We worked closely with Farmers Air Personnel for design advice and Aeromotive who were responsible for embodiment.

The result of this project has been a significant improvement in aircraft reliability and reduced maintenance costs.

Airworthiness approval of the new flap system design was by a CAA STC which is which may be incorporated on any PAL 750XL operating in New Zealand or Australia.

The Farmers Air aircraft also embodies a 3000 litre capacity hopper, which also has CAA STC certification. Please click here for more information on the hopper.

Medical Refit of PSRT Westpac Air Ambulance

Wed, 02 Apr 2014 00:00:00 +1300

In December 2013 the Prime Minister John Key launched the new Waikato Westpac Air Ambulance (BK117 B-2) at Hamilton International Airport. Flight Structures played an important role in getting this aircraft in the air.

The Westpac Air Ambulance is used for both medical transfer and search and rescue operations and quick change of role equipment is vital when responding to various emergency scenarios.

Philips Search and Rescue Trust, (the operator) approached Flight Structures to develop a restraint system to accommodate both the Stryker and Ferno Stretchers. The design is unique because it allows a quick (less than one minute) changeover between systems.

Flight Structures was successful in gaining approval of the stretcher restraint design by issue of a CAA STC which may be incorporated on any BK117 helicopter operating in New Zealand or Australia.

Several other modifications were involved in the refit of the aircraft including:

Stretcher interface for carriage of Neo-Natal Incubators;
Skid mounted “Snow Shoes” to allow landing on soft terrain;
Weather Radar installation;
A/C electrical power supply;
LED spotlight for night time stretcher loading.

Flight Structures partnered with TechAir (avionics suite) and Hamilton Aero Maintenance (embodiment) to ensure that the BK117 met the operational requirements of the PSRT.

This project took approximately six months and has had positive feedback from both the Trust and the medical crew.

For more information about the Philips Search and Rescue Trust please click here .

Phillips’ BK117 B-2 also incorporates the 850hp engine upgrade. For more information on this upgrade please click here.

Flight Structures Celebrates 10 years of Business

Wed, 13 Nov 2013 00:00:00 +1300

Recently Flight Structures celebrated ten years of business with a company celebration dinner in Hamilton.

Jon Kerr, Chief Executive, and Richard Andrews, Chairman, have both been with the company since inception in late October 2003. At that stage Flight Structures had one staff member, Clyde James who is still employed within the company as Chief Draughtsman.

Since this time we have grown to have two offices with 13 staff plus contractors, many of whom have been with the company for over five years. Flight Structures has worked with most of NZ's leading aviation companies, and on many international projects. The company has evolved to include a manufacturing arm and increasingly we are working on design and build projects.

Flight Structures gains CASA PNG Delegation

Mon, 12 Aug 2013 00:00:00 +1200

We are pleased to announce that Flight Structures Limited is now a Design Organisation under the Civil Aviation Safety Authority of Papua New Guinea. Jon Kerr, Murray McGregor and Chris Raynes have all gained delegations to certify and approve aircraft modifications in PNG.

If you are interested in our services in this area then please contact one of the above engineers in our Hamilton office

Contact Details

Crew Seat now certified in Australia

Wed, 17 Apr 2013 00:00:00 +1200

Flight Structures Ltd has been successful in gaining an STC for the Medical Crew Seat in the Hawker Beechcraft 1900D. This certification is applicable to both NZ and Australian aviation industries.

For more information about the Medical Crew Seat please click here

SAAF install Airwork (NZ) BK-117 Sand Filters

Wed, 12 Dec 2012 00:00:00 +1300

The South African Air Force (SAAF) have reported they are very happy with the performance and capability of the Airwork (NZ) Ltd BK117 Sand Filter. Flight Structures was contracted by Airwork (NZ) Ltd to complete the Design and Certiifcation of the Sand Filter system and gain NZCAA STC Approval for both KHI and MBB models.

Significantly, through a combination of detailed design development, system safety analysis, performance modeling, and flight testing, Flight Structures was able to approve the system for Category A operations and remove the substantial performance penalties applied to the OEM system.

Excerpts from the November 2012 issue of Global Aviator magazine:

"Initial results have proven most favourable with pilots claiming a reduced engine operating temperature. This is significant as this reduces engine stress (fatigue) and therefore extends engine life and increases mean time between overhauls while also increasing mean time between failures of related engine components. These all have positive cost implications, more especially in the long term.

From an aerodynamic perspective, besides the superior aesthetics ('Miss' BK claims to have had more requests for her telephone number than ever before!) a significant reduction in frontal drag has favourable implications in terms of increased maximum and cruise speed, longer range and increased endurance etc.

Unlike the earlier system, the Airwork system is certified to meet full Category A and B transport requirements.

At 32 kg (70.5 lbs) installed weight all told (including all electrical components), the new system is 12.5 kg (27.6 lbs) lighter than the system it replaces."

Read the full pdf article below:

life and increases mean time between

overhauls while also increasing mean

time between failures of related engine

components. These all have positive cost

implications, more especially in the long

term. From an aerodynamic perspective,

besides the superior aesthetics ('Miss'

BK claims to have had more requests for

her telephone number that ever before!)

a significant reduction in frontal drag

has favourable implications in terms of

increased maximum and cruise speed,

longer range and increased endurance etc.

Unlike the earlier system, the Airwork

system is certified to meet full Category A

and B transport requirements.

At 32 kg (70.5 lbs) installed weight all

told (including all electrical components),

the new system is 12.5 kg (27.6 lbs) lighter

than the system it replaces.

Global Aviation Magazine Article

Four STCs in one month!

Tue, 23 Oct 2012 00:00:00 +1300

Over the last month, Flight Structures has been successful in gaining four Supplementary Type Certificates (STC's) for our client organisations. STC's are a type of design change approval that offer several advantages over standard 'Form 337' approval. STC approval is especially beneficial if you intend to embody your design on several aircraft, or wish to sell your modification to other organisations or operators.

STC's are issued by the NZCAA, however the support of a Part 146 organisation such as Flight Structures Limited is normally required. Flight Structures has significant experience with the preparation of the required documentation and design data for STC applications. In addition we can provide liaison with the NZCAA, which ensures your application is approved efficiently and effectively.

Contact Flight Structures if you would like to learn more about what STC approval can offer you.

Fitout for NEST Sikorsky

Tue, 11 Sep 2012 00:00:00 +1200

In 2012 Northland Emergency Services Trust refitted ZK-IKM, one of their three Sikorsky helicopters. The fitout involved installation of two aft facing crew seats designed and manufactured by Flight Structures. The seats have a four point harness.

The new seats allow the crew to rest as much as possible during long night flights, reducing fatigue.

Northland Emergency Services Trust are based in Whangarei, and provide a rescue service to Northland and beyond.

Here is a link to their website.

NEST website

Here is the link with more details about the Crew Seat.

Specifications of Crew Seat

New Crew Seats for Philips Search and Rescue Trust AS350 Fleet

Fri, 07 Sep 2012 00:00:00 +1200

Flight Structures have successfully developed a short rear crew seat for Philips Search and Rescue Trust fleet of AS350 'Squirrel' helicopters. The seat which folds up out of the way, uses existing harnesses, and can be placed at either side of the cabin. This allows a stretcher to fit in the helicopter when required. The seat was designed and manufactured by Flight Structures.

The seat is available to purchase from Flight Structures as an off the shelf solution, please contact Jon Kerr on 07-843-1128 for more information.

Philips Search and Rescue Trust operate 5 helicopters in the North Island, providing rescue services throughout the Waikato, Bay of Plenty and Central North Island. Here is a link to their website.

Philips Search and Rescue Trust

R66 Spray System STC

Tue, 24 Jul 2012 00:00:00 +1200

Flight Structures Ltd has certifed a purpose designed spray system for the latest Robinson turbine powered R66 rotorcraft. The light weight spray system consists of carbon fibre tank and booms, and incorporates the latest in calibrated GPS rate controllers to ensure efficient and environmentally friendly disperson of agricultural product.

The project was lead by Outgo Aviation Ltd, who specialise in sustainable and profitable farm fertiliser programmes. STC approval for the R66 is expected in August 2012.

Jetstream 31 conversion to Aero Medical Use

Thu, 31 May 2012 00:00:00 +1200

Recently Flight Structures Ltd approved a major design change for Wellington's Life Flight Trust, where a Jetstream 31 was converted for aero-medical use. This project which was completed in under two months, involved refitting the aircraft with new Flight Structures seats, designing and approving stretcher bases and certification of the back up battery system. The fit out was completed by Vincent Aviation.

You can also refer to the May/June 2012 issue of Vector Magazine, titled "Design Delegation Holders" where the CAA explain how delegation works, referencing this project.

Link To May/June 2012 issue of Vector Magazine

For more information on the Life Flight Trust please refer to their website.

Link to Life Flight Trust

To see footage of the aircraft, including the unique paintwork created by Weta Workshops please follow the link to the 3News website.

Link to 3News

EASA STC awarded to Airwork BK117-850D-2

Thu, 08 Mar 2012 00:00:00 +1300

We are proud to announce that EASA has awarded Airwork (NZ) Ltd STC approval for the BK117-850D2. The remarkable new engine upgrade that is proving hugely popular with operators throughout Australia, New Zealand, and surrounding countries will now be available for use in European countries, and countries which recognise EASA STC approval.

The award concludes a thorough certification program, run by Flight Structures Ltd in conjunction with Airwork (NZ), Honeywell, and AeroDAC.

Flight Structures Engineer Henry Dumbleton remarks "The project has been punctuated by some really spectacular moments. We 've flown to some amazing places and worked with very talented people. The project has really come together and we're ecstatic with the result for our client".

The project is technically very satisfying from an engineering perspective, with the development of a specific BK117 performance modeling program and culminating in dramatic demonstrations of the helicopters new capabilities.

Flight Structures has enjoyed working with EASA on this project and looks forward to bringing more New Zealand and Australian aeronautical products into the international market

Link to Airwork (NZ) Ltd's BK117-850D2 Website

Flight Structures Ltd soars into manufacturing

Mon, 27 Feb 2012 00:00:00 +1300

The article below appears in the February 2012 edition of NZ Manufacturer magazine. Here is the link to the magazine.

Read the NZ Manufacturer Article here

Flight Structures Ltd soars into manufacturing

A new aviation manufacturing facility is setting up shop at the Hamilton Airport. The company, Flight Structures Manufacturing, is a joint venture between Flight Structures Ltd and Clevedon Aeroplane Company Ltd. The companies look to expand their scope of services to meet the current demands and future demands of aviation manufacturing.

Jon Kerr of Flight Structures Ltd, said it is an undertaking he had been thinking about for many years now. “As we have grown,” he said. “It just seemed the logical next step. It’s a great way to expand the business and allows us to not only offer our customers a turnkey solution but also allows us to utilise the rich resources of aviation expertise we have all around us. Together we are definitely a little bit greater than the sum of our parts.”

Flight Structures Manufacturing will provide design, certification, manufacturing and installation for special role modification aircraft and helicopters. According to Mr Kerr, because these like-minded companies surround it, it will be able to pull from ready available resources. These resources include Alpha Aviation, which produces the Alpha 2000 Series training aircraft and the Clevedon Aeroplane Company. The Clevedon Aeroplane Company specialises in the manufacture of aviation products and installation of aircraft modifications and repairs.

Jon and business partner Richard Andrews founded Flight Structures Ltd in 2003 as an engineering consultancy service. They provide professional design and certification services to the aeronautical industry and have become the largest aeronautical design and certification consultancy in New Zealand.

Starting with a staff of only three, Flight Structures currently employs over 17 people with a variety of experience and skills. “With Flight Structure Manufacturing we will not only be able to utilise our current staff more effectively but will also have the opportunity to bring in others, creating a knowledge base that can’t be beaten,” Mr Kerr said. “We will be able to offer huge value to our present and future customers.”

The new facility will boast the first commercial installation of the American made C.R. Onsrud brand CNC Router in New Zealand. A full technological solution, the C.R. Onsrud machine will be used to manufacture Flight Structures designs of aircraft prototype parts. “Parts designed in the morning can be transferred directly to the machine and manufactured onsite in the afternoon” said Mr Kerr.

“This will save our customers time and money,” said Gary Peace co-owner of Flight Structure Manufacturing and Company Director of Clevedon Aeroplane. “We will be able to supply 24 hour technical support when it’s needed.”

“Jon and I have worked together for years. When he approached me with the idea of this venture and the C.R. Onsrud machine – it just seemed too good to pass up,” said Mr Peace. “The C.R. Onsrud machine will give us that flexibility to do the work ourselves and not have to wait on others.”

As the first of its type in Australasia, the C.R. Onsrud machine is being distributed by MPB Engineering PTY Ltd out of Australia. “The majority of our work had been with sawmill and timber industries but now as the new agent for the C.R. Onsrud machines in this area, we are able to offer services to even more industries including aviation,” said Braydon Cocks, Account Manager for MPB Engineering PTY Ltd. “Our engineers have been working with all types of CNC Routers for a long time but we have been truly impressed with the C.R. Onsrud machine.”

MPB Engineering is a second-generation family company, which has been in business since 1974. The core element of the business is the design, manufacture, service and sales of woodworking equipment and now aviation. With a full staff of engineers, the company prides itself on custom made machines that are designed to a very high standard.

“We are really looking forward to working with Jon and his team,” said Mr Cocks. “Jon was serious about quality when he went looking for a CNC Router. He’s the type of customer that is a perfect fit for us. Our focus is completely on the quality of our products. Everything has to be just right.”

According to Mr Cocks, the decision to go with the C.R. Onsrud products was an easy one because it is a company that shares the same values as MPB Engineering. The C.R. Onsrud Company, based out of North Carolina, USA, is family owned and specialises in top-notch CNC machinery designed for the aerospace, woodworking, plastics and composites industries. All machines are designed and manufactured at the North Carolina facility.

The company has been in business since 1915. The founder, Charles Onsrud, patented the “Inverted Router” in 1976. The idea made a huge impact on the woodworking industry by increasing safety and usability. Since then, the Onsrud name has been known for quality and value. They have been building computer-controlled routers like the one purchased by Flight Structure Manufacturing since the late 1950s.

“The router will offer Flight Structures Manufacturing a terrific amount of flexibility,” said Mr Cocks. “There is a huge range of usage on this type of router – from big to very small pieces.“

“This type of router has been in many parts of the world for awhile now but this is the first time we’ve had one in New Zealand and coming down here to train everyone seemed a great excuse to see a beautiful country,” Mr Onsrud laughed.

Mr Onsrud went on to explain that besides a knowledgeable agent, C.R. Onsrud also is able to provide online diagnostics through any device that is set up to talk to the CNC router. “Service means everything to us. If we can’t diagnose an issue through our online service, then our partnership with MPB Engineering is going to ensure that Jon and his team’s machine keeps running.”

“It’s great that we are all in this together,” commented Mr Kerr as he looked around at the group being trained. “It’s a good example of local companies collaborating for a common goal.”

Flight Structure Manufacturing is located on Steele Road by the Hamilton Airport.

Chinese Civil Aviation Visit

Mon, 20 Feb 2012 00:00:00 +1300

Hamilton Airport was visited by representatives of the Civil Aviation Administration of China. The visit was part of the certification of the Alpha Aviation aircraft into China.

In the first picture CAAC-AAD Deputy Director General Yin Shijun tries out the Alpha 160A cockpit while Zhu Xuefeng Engineer Aircraft Certification Division looks on.

In the second photo Jon Kerr summarises the Alpha aircraft certification to CAAC-AAD Deputy Director General, Yin Shijun, Director, Aircraft Certification, Yang Zhenmei Division, and Engineer Aircraft Certification Division, Zhu Xuefeng.

Slurry Spray System Designed and Certified

Wed, 16 Nov 2011 00:00:00 +1300

Flight Structures has designed and certified a Suspension Fertilizer Application System. Application of agricultural fertilizer as a sprayed liquid with the fertilizer in suspension is a method that is becoming increasingly popular with farmers.

Farmers Air recently tasked Flight Structures with the design and certification of a suspension fertilizer application system on a Pacific Aerospace Cresco aircraft. The system developed permits spraying at the very high rates required to allow the high performance and productivity potential of the Cresco to be realised. A commitment to maximising aircraft performance required the use of a hydraulically driven main engine powered spray pump (with a power capacity of 40 kW), together with attention to minimising the drag of external spray system features.

The time from the start of the design project to final installation and certification was eight weeks. The result is an installation that is practical, easy to maintain and which, in service, has demonstrated unprecedented productivity.

Flight Testing in Papua New Guinea

Tue, 27 Sep 2011 00:00:00 +1300

Flight Structures Ltd Engineers Jon Kerr and Henry Dumbleton have just returned from a successful flight testing programme in the highlands of Papua New Guinea. The objective was to test Airwork (NZ) Ltd’s BK117-850-D2 in hot and high conditions together with a visiting EASA flight test team. The programme was led by Flight Structures and involved a large international team, including staff from Airwork (NZ) Ltd, Helilink and Heli Niugini. The successful completion of the testing is a major milestone and paves the way for EASA certification of Airwork (NZ) Ltd’s powerful new BK117. &amp;amp;amp;amp;amp;amp;amp;amp;amp;lt;/p&amp;amp;amp;amp;amp;amp;amp;amp;amp;gt;

Flight Structures adds manufacturing capability

Fri, 19 Aug 2011 00:00:00 +1200

Flight Structures is adding manufacturing to their design capability, heralded by the new CNC Router Machine imported from the USA which arrives in October. The company will continue to focus on prototype developments and are in the process of gaining a CAA Part 148 manufacturing certificate. We will be able to offer a complete solution to our clients reducing costs and working to tighter timeframes. The machine will also be used to manufacture the Flight Structures Crew Seat.

Read the NZ Manufacturer Article here

STC Issued for Falco 3000XL

Tue, 09 Aug 2011 00:00:00 +1200

The Supplementary Type Certificate for the Farmers Air Ag Conversion of the 750 XL has been issued. Flight Structures completed all the design, project management, flight testing and CAA requirements, working closely with Farmers Air pilots and engineers. Partnering companies were Aeromotive, Pacific Aerospace Limited, Av Parts and Composites International.

The 750XL was modified by removing unnecessary weight, installing a light weight high strength carbon fibre hopper, and incorporating a barrier air filter into the streamlined cowl. Farmers Air pilots were heavily involved in the design and their input influenced modifications to increase the rudder power for improved cross wind performance and reducing the elevator forces to reduce pilot fatigue. The aircraft has a 2200 litre hopper capacity with a 2200kg payload. Crunch the numbers and you will find the Falco3000 is the least expensive platform to spread fertilizer by air.

FALCO 3000XL Agricultural Aircraft set to improve productivity, crew comfort, and safety.

Thu, 16 Dec 2010 00:00:00 +1300

Flight Structures, working with Farmers Air Ltd, have designed and approved a major modification to the PAL 750XL airframe, christened the FALCO 3000XL. The main design features are a lightweight 3000 litre carbon fibre hopper, 2000 kg payload and a new streamlined light weight cowling with improved air filtration.

The FALCO 3000XL builds upon the proven ability of the Pacific Aerospace aircraft, including the Fletcher, Cresco, and 750XL to offer a replacement aircraft for those no longer in production. The 750XL cockpit has been further improved and offers excellent leg room, a quieter environment and better ergonomics for a less fatigued pilot.

The aircraft also features a large hopper lid to minimise spillage, Agricultural GPS and GPS Tracking equipment, and a substantially revised fuselage structure which integrates the hopper as load bearing structure.
View of the FALCO 3000XL brochure here

Airwork (NZ)’s BK117-850D2 takes to the skies over Australia and New Zealand

Sat, 01 May 2010 00:00:00 +1200

Airwork (NZ)’s BK117-850D2 has taken to the skies over Australia and New Zealand, with approval in Europe and America set to follow.

Flight Structures has led a highly successful certification program for the BK-117B-2, which concluded May 2010 with the issue of a NZCAA Supplementary Type Certificate. Flight Structures has worked closely with Airwork (NZ) and Honeywell on the development of the BK117-850D2, which incorporates the latest technology 850 hp engines from Honeywell, with spectacular performance results that have exceeded expectations.
One of the most challenging aspects of the program was the determination and validation of improved performance. For this Flight Structures Ltd designed and developed a computer based performance model to map the engine installation, rotor performance, and airframe aerodynamics to predict all aspects of the performance envelope.

Flight Structures flight test engineers validated the calculated performance over several month of testing, culminating in flawless demonstrations of Category A vertical take-off simulated engine failures at maximum certified weight on a hot summers day.

The successful management of this project has shown that Flight Structures has the knowledge, experience, and capacity to deal with large-scale international projects, and deliver quality results on time with excellent value for money.

Flight Structures continues to work with Airwork (NZ) on EASA and FAA approval of the BK117-850D2 expected late 2010/early 2011.

Read more about the upgrade in this NZCAA Vector article
Or download Aiwork (NZ) Ltd's Brochure

Flight Structures becomes official Supplier to Royal New Zealand Air force

Sat, 07 Nov 2009 00:00:00 +1300

Flight structures has become an official supplier to the Royal New Zealand Airforce. Flight Structures will provide specialised design services to the New Zealand Defence Force in an agreement reached last week [read more] that accepts Flight Structures as an officially registered supplier of design and certification services and aeronautical products.

Flight Structures has an extensive history of design and certificaion of role equipment, with literally thousands of jobs in our books. This depth ensures that we offer the highest quality solutions which are dependable in the most demanding operating conditions.

Medical Transport – Hawker Beechcraft 1900D

Fri, 24 Apr 2009 00:00:00 +1200

Flight Structures has completed a milestone Design, Build Management, and Certification project with the creation of a Medical Transport system for Hawker Beechcraft 1900D aircraft.

The design features three stretchers, each with specialised medical equipment, and tailored rearward facing seats to allow medical staff to tend to patients. Additionally five forward facing seats are provided for medical professionals, or other occupants.

The increased capacity of the medical transport aircraft presents a highly desirable configuration, which is set to surpass smaller aircraft in terms of efficiency, cost, and operational effectiveness.

Remarkably, the completed medical transport was flying within four months of conception; once again demonstrating the market leading ability of Flight Structures to tackle large projects quickly and effectively.

Successful Static Testing of Seat Design

Wed, 01 Apr 2009 00:00:00 +1300

Flight Structures has successfully completed structural testing on it is all new forward and aft facing seat, destined to be installed as part of a medical transport/evacuation installation in Hawker Beechcraft 1900D aircraft. The composite seat offers the operator the unique ability to install the seat on the port or starboard side of the cabin, in forward and aft facing configurations, making the seat a flexible and attractive option for various aircraft types and roles, from full cabin retrofits, to one-off role specific installations. The seat interface is specifically designed to suit the 1900D cabin, but will be adapted for use in other aircraft types.

Prototype Aircraft Seat Completed

Thu, 30 Oct 2008 00:00:00 +1300

Flight Structures has made prototype aircraft seats, targeted at the new generation general aviation aircraft. The crew and passenger seat share the same high quality comfort and safety features, with the addition of horizontal and vertical adjustment to the crew seat. Initial certification will be demonstrated for the 9g forward emergency landing criteria applicable to aircraft designed prior to 1987. However the intention is to certify the seats to the latest amendment of FAR 23 and 25, which will require dynamic (crash) testing at laboratories in the USA. The Flight Structures seat is designed to be lightweight and comfortable and meet the criteria of TSO C117.

Agreement Signed with Manufacturer

Fri, 26 Sep 2008 00:00:00 +1200

Flight Structures has concluded an agreement to provide design and certification services to Pacific Aerospace Limited, Australasia’s largest aircraft manufacturer. Many of Flight Structures senior staff started their careers in the PAL design office and were heavily involved in the original development and certification of the PAL 750 XL, CT4/E Airtrainer, and Cresco aircraft.

Flight Structures achieves major milestone

Sat, 16 Jun 2007 00:00:00 +1200

Flight Structures has achieved a major milestone for Alpha Aviation with the issue by Type Certificate for the Alpha HR200 and R2000 series aircraft by the CAA of New Zealand. The Type Certificate has been transferred from the previous holder, Apex Aircraft in France, to Alpha Aviation Design Ltd in New Zealand. Subsequently the European Airworthiness Safety Authority (EASA) has also transferred their Type Certificates to Alpha Aviation. Issue of the Federal Aviation Administration (FAA) Type Certificate is expected in the near future.
Flight Structures were awarded a three year contract by Alpha Aviation to establish, manage, and staff Alpha Aviation Design in 2004. Flight Structures’ first task was to create the design procedures which allowed Alpha Aviation Design to be issued a CAR Part 146 Design Organisation certificate in January 2006. Simultaneously Flight Structures implemented the design changes requested by Alpha Aviation into the Alpha 160A aircraft. These changes included a new instrument panel, engine air inlet and exhaust systems, and new electrical wiring loom.

CAA took and active role in the Type Certification process by conducting a conformity inspection of the first Alpha 160A aircraft, review of engineering reports and Flight Manuals. They also had their test pilot conduct a series of audit test flights to ensure that the original flight characteristics had not been affected. An important feature of the certification process was the early involvement of CAA which meant that the significant certification issues were resolved well in advance of the anticipated completion date.

With the issue of the Type Certificate achieved Flight Structures’ involvement with Alpha Aviation will switch to supporting the Alpha 160A production line and providing technical support to the 300 existing HR 200 and R2000 aircraft operators spread throughout the world.

Circle-the-Earth with Flight Structures’ Ferry Fuel System

Thu, 14 Sep 2006 00:00:00 +1200

Flight Structures is pleased to announce that the Circle-the-Earth crew have departed on their round the world flight to raise funds for Starship Children’s Hospital. The three pilots will be circling the world in a modified Cessna 421B twin engine aircraft. Flight Structures provided the engineering support required to install and certify the four ferry fuel tanks and associated fuel system modifications for an extra 970 litres of fuel. The maximum certified take-off weight was also increased by 1250 pounds (17%). Good luck to Alistair, Joe, and Flora, the Circle-the-Earth pilots.