Flight Structures Services

With the proven ability to provide services ranging from aeronautical engineering advice to full in-house design control, Flight Structures is an excellent partner to bring to your business.

Certification of Aircraft and Rotorcraft Modifications

1. Design and Certification of Aircraft Designs
2. Aircraft Type Certification
3. Structural Repair Design
4. Fatigue Safe Life Extensions and Safety By Inspection Programmes
5. Transport Aircraft Interior Reconfigurations

1. Design and Certification of Aircraft Designs

Flight Structures perform the work necessary to certify your aircraft or rotorcraft modification design to the applicable airworthiness requirements. As a CAA approved Part 146 Design Organisation, Flight Structures will assess your modification, recommend design changes (if necessary), and then prepare the documentation for CAA approval.

For New Zealand registered aircraft, Flight Structures has delegated powers from CAA to approve modifications to aircraft up to 63,000 kg (138,850 lbs) and rotorcraft up to 6,200 kg (13,665 lbs). For aircraft that are not New Zealand registered, Flight Structures will liaise with the applicable country’s airworthiness authority to obtain a Supplemental Type Certificate (STC), or equivalent, for the customer’s design.

The ideal aircraft modification is easy to install, lightweight, streamlined in design, and effective in its function. Flight Structures are specialists in the design and certification of metal aircraft structures.

2. Aircraft Type Certification

The senior personnel within Flight Structures have a high level of experience in the Type Certification of aircraft to Federal Aviation Requirement (FAR) Part 23. This process requires a broad range of skills to demonstrate compliance to the myriad of airworthiness requirements as well as the ability to successfully liaise with airworthiness authorities.

Type Certificates for the New Zealand made Alpha 160A

3. Structural Repair Design

An effective repair is one that is implemented quickly and more cost effectively than replacing the affected structure. Flight Structures provide structural repairs that restore static strength but also do not adversely affect the damage tolerance or fatigue characteristics of the affected structure. Finite Element Analysis (FEA) and 3D design software is employed to design optimise repair parts and minimise stress concentrations within the affected structure.

Skin repair following wheels-up landing

4. Aircraft Fatigue Life Extension Programmes

In some cases it is possible to extend the service life of aircraft or major structure beyond the manufacturer’s Fatigue Safe Life Limit. Flight Structures can evaluate an aircraft’s flight load spectrum and determine if an extension to the fatigue life is possible. Alternatively, it may be possible to develop a Safety by Inspection (SBI) programme, based on a Damage Tolerance Analysis (DTA), whereby the aircraft continued service is based on regular inspections of the fatigue critical structure.

Wing Structure Model - Crack Growth Analysis

5. Transport Aircraft Interior Reconfigurations

Transport aircraft are often reconfigured to accommodate the operator’s specific requirements. Flight Structures can certify the interior reconfigurations that include changes in seat layout, emergency equipment, cargo compartments, and galleys.

Boeing 737-300 Seat Layout