Flight Structures News

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.