Flight Structures News

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;lt;/p&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.

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.