JETSTREAM 31 CONVERSION TO AERO MEDICAL USE

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.

EASA STC AWARDED TO AIRWORK BK117-850D-2

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

FLIGHT TESTING IN PAPUA NEW GUINEA

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.

FALCO 3000XL AGRICULTURAL AIRCRAFT SET TO IMPROVE PRODUCTIVITY, CREW COMFORT, AND SAFETY.

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.

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.   

AIRWORK (NZ)’S BK117-850D2 TAKES TO THE SKIES OVER AUSTRALIA AND NEW ZEALAND

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.

FLIGHT STRUCTURES ACHIEVES MAJOR MILESTONE

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.