Flight Structures Ltd Achieves CASA Papua New Guinea Part 146 Certification
We are proud to announce that Flight Structures Ltd has officially received CASA Papua New Guinea Part 146 Design Organisation Certification.
This significant milestone was achieved following a successful onsite audit conducted by Clancy Pulti (Senior Airworthiness Inspector) and Arthur Gabi (Airworthiness Inspector) from CASA PNG, during their visit to our facility on 26–27 May.
We thank the team from CASA PNG for their professionalism throughout the process, and we extend our sincere appreciation to everyone involved — both in Papua New Guinea and on our team — who worked hard to make this certification possible.
This achievement reflects our continued commitment to supporting our client base and growing our capability.
Sally Kerr, John Kerr, Clancy Pulti, Daniel Mossman and Arthur Gabi
What’s been happening in 2025?
2025 started in an extremely busy fashion. There has been a lot going on and there will be news stories coming soon regarding projects that are nearing completion.
In today’s work place we want to keep our staff learning and developing, both intellectually and building a strong team ethos. Here are some things we have been doing to try and do this.
Lunch and Learn
Each winter we hold internal CPD sessions and this year we are doing this over “lunch and learn” sessions. We called upon two of our graduate engineers to present on topics close to their heart. It is motivating to see how staff work as volunteers to develop and support their passions. We all learnt a lot.
One engineer talked about his project launching and competing in SpacePort USA in 2024. UC Aerospace rockets to victory at Spaceport America Cup | University of Canterbury.
Another engineer presented about his role as a race car engineer in the Toyota 86 Series where drivers compete for the GR Racing Cup, and how engineers and teams enhance car and driver performance.
In addition, one of our senior engineers led learning on the topics of the development of the CT4 aircraft and the programme behind this, and on wing stress analysis.
Velodrome Racing
On Saturday five staff competed in the Corporate Challenge at the Grassroots Community Velodrome. This year we entered in the Team Pursuit where the four riders tackled eight laps (2000m) and riders rotate positions to maintain pace. The team was a mix of experienced and novice riders, and for the first time we were successful in getting a woman on the team. Well done to the team who got a fourth place in their category.
University of Waikato Astronautics Club Rocket Launch
Flight Structures is proud to sponsor the University of Waikato Astronautics Club. On the 8th of June the club conducted a final test flight for Takahe which is competing at the Australian Universities Rocket Competition (AURC 2025). If you look closely at the photos you can see our logo on the rocket.
Below is a carousel of photos of some of the events over recent weeks.
Highlights in October and November.…
We have been extremely busy through October and November. Here are a few photos of recent days in the life of Flight Structures.
Our Chief Operating Officer and Manufacturing Coordinator both attended the Women in Airports and Infrastructure event;
Our Machine shop and router have been well utilised making role equipment;
Manufacturing snowshoes for a new client;
Teaching interns and new staff about our work and our processes;
All hands were on deck to prepare for a structural test in our workshop, (navy seemed to be the winner on the day).
September conferences in Ōtautahi..
Some of our team visited the Garden City of Ōtautahi in late September to attend two conferences. Firstly the New Zealand Aerospace Summit where we were proud to partner with Merlin and Beca to promote the Merlin pilot, which provides advanced autonomy enabling full takeoff to touchdown flight. It is exciting to contribute to this programme, and be involved in New Zealand.
Team FSL also then had a stand at the 2024 Aeromed Conference - a great chance to show off our products to the market, meet with our clients. A couple of our engineers enjoyed role playing in the AMSL Vertiia, a solution for zero emissions flying.
And we also met a dog from the future, thanks to SPS Automation. She was very obedient and clean.
A win in the Corporate Challenge
Since 2017 Flight Structures has been entering a team in the Corporate Challenge. This year our team won the Men’s Italian Pursuit!! Well done to current team members Clyde, Scott, Adam, Brandon and James, with thanks to previous team members Jon, Brett and Hemi.
Super Falco departs Hamilton Airport
In April ZK-XLA received a Certificate of Airworthiness from the CAANZ….. and departed Hamilton with a loyal Flight Structures fanbase viewing her flight.
The Super Falco was developed by Andy Stevenson Aviation in conjunction with NZ Aero, with Flight Structures providing design and certification support. For more information on the Super Falco you can refer to this link.
We look forward to seeing her back here again at some stage in the future.
Movers and Shakers in March
Whilst in some ways March was a “Business as Usual” month there have been many exciting things happening.
The most time consuming was the move of our workshop to our new premises - an especially large job involving the relocation of our large flat bed router and the arrival of our new vertical machining centre. Keeping on with client work during this process was achieved and we are pleased to have the bulk of the work completed. The photos below capture some images of the move. The VMC is up and running now providing extra capacity.
In March we hosted Keith Manch, Director of Civil Aviation of NZ along with Peter Gordon, also from CAANZ. We gave Keith a tour of our (newly relocated) premises and demonstrated some of the projects we are working on. We appreciated the opportunity to talk through our part of the aviation landscape - he is the first director in 20 years to take the time to come and visit.
Right at the end of March one of our team (David Roberts) headed to the Warbirds over Wanaka Airshow and took a photo of the V12 Fletcher. This project has been a long term project for Bill Sutherland and we understand it was a very popular display. David is a very keen photographer and has over 1000 photos from the airshow for us to look through.
And lastly, when we had a celebratory BBQ to welcome the workshop team to our Boyd Road building - we literally walked outside to a practice display by the Yak team practicing for Warbirds over Wanaka. It felt like it was especially for us (some of us may have pretended that it was). Below you can see a small snippet of some video footage at the airfield taken by one of our staff members.
It is great to finally be under one roof as a team. There are positives with remote working (we do have staff partly using this model) but there are so many good things about sharing a workspace and the collaboration this allows.
Supplemental Type Certificate for Super Falco Achieved......
At the very end of 2023 we received notification of the Supplemental Type Certificate (STC) for the Super Falco, a development owned by Andy Stevenson Aviation. This was very exciting as the programme to certify this aircraft was run in tandem with the SuperPac Certification programme of NZ Aero.
STC 22/21E/15 covers the installation of an upgraded powerplant to PAL 750XL aircraft configured for agricultural operations by STC 11/21E/8 and STC 13/21E/4.
The powerplant upgrade consists of the installation of a Pratt & Whitney Canada (PWC) PT6A-140AG turbo-prop engine and 4 blade Hartzell HC-E4N-3KA() / E10703S() propeller.
Changes associated with the powerplant upgrade include a lengthened nose gear to accommodate the propeller, installation MVP-50T engine gauge, 30° landing flap setting and Elevator Trim/Balance Tab travel changes.
Jon Kerr was the Senior Project Manager on this project, assisted by the team including Jamie Simmons, Scott Simpson, Clyde James, Duncan Wollen, Adam Jones, Murray McGregor, David Roberts and Hemi Jones. Partners in this project were Menzies Aviation (Hamilton Aero Maintenance), Andy Stevenson Aviation and final sign off was by the Civil Aviation Authority of New Zealand.
Jon Kerr states “We made the best ag aircraft in the world better. It was a fantastic team effort by all involved and we look forward to the C of A being completed soon”.
Just in time for Christmas - incubator job completed...
Just in time for Christmas (or on the Summer Solstice, the 21st of December) Flight Structures completed this worthwhile project.
The 8-week long project involved retrofitting and modernising the WDHB Incubator medical modules to a newly modified Flight Structures sled. The purpose of this project was to allow compatibility with both Life Flight’s Beechcraft B200 aircraft fleet and Search and Rescue Services Ltd.’s BK117 B-2 helicopters.
The completion of the project provides seamless integration between the Wellington and Waikato Incubators in the Beechcraft B200’s. Both are installed making use of the previously installed FSL restraints and TAS Aeromedical Stretcher Lifting Device to allow simple and easy loading of the Incubator Medical Modules, even in the worst of conditions.
Utilising the Flight Structures BK117 Stretcher Restraint System, the upgraded WDHB incubator modules remain capable to be carried in the BK117 helicopters further increasing the range of transfer locations.
This project had a tight timeline and we delivered the B200 module by the 14th of December and the BK117 module by the 21st of December. We have already seen the B200 in action transferring babies and whanau. Both Life Flight Trust and Philips Search and Rescue Trust provide a wonderful service to those in need.
Congratulations to the Project team - photographed below - which involved a mix of Design, Certification, Project Management, Manufacturing and Administration staff.
A night out at the Waikato Business Awards
After 20 years we decided to enter the Waikato Chamber of Commerce Business Awards, in the Innovation Category (sponsored by Company X). Whilst we did not win the category we were delighted to be selected as a finalist, and to attend the fabulous evening with some of our team. Going through the award entry process- both nomination and judging - was a worthwhile exercise in seeing how our business has developed and endorsing of the company we have created.
The winner in our category was Emergency Consult, who were very worthy of this trophy. They deliver urgent medical advice using video technologies. The other finalist was Helix Flight Manufacturing Machines, another great Waikato engineering company.
Being a finalist meant we had a promotional video put together by INDx Media, thanks to Borden for all his support. Please check it out at the top of this post.
Photos on the night were taken by Barker Photography, who made most of us look good, and there are some casual snaps of the night added in as well.
I would recommend entering the awards to local businesses who want to experience a top quality event and grow their business. The Waikato Chamber of Commerce did a wonderful job of making the whole process smooth and professional.
