Items in Stock
As of early November 2022 Flight Structures has the following items in stock or within a week of being completed:
BK117
Snowshoes
3 Pax High Density Seat
AW169
RULS Stretcher Loading System
Free Standing Rack
THRULS Trolley
750XL
Vortex Generators
Drive Shaft Assemblies (Wet or dry spine)
Please contact Sally at Flight Structures if you need any further information about these products, or would like a quote.
Professional Development for NZ Aerospace Engineers
During 2021, Flight Structures took over the responsibility of running the monthly Continued Professional Development (CPD) Zoom sessions for New Zealand Aerospace Engineers, as part of the Royal Aeronautical Society (RaeS) New Zealand Division.
These presentations have covered a range of topics with a main focus on subject areas within aviation. The aim of the sessions is to educate the wider NZ Aerospace community on current and future advancements happening within the industry.
Since the start of 2022, we have had a range of different presentations:
Gary Freedman from Electric Air informed the audience about his Pipistrel Alpha Electro which he recently used to set the record for the first person to fly across New Zealand’s Cook Strait in an electric plane.
Akesh, a PhD student from RMIT University, shared his research into 3D Printed Aircraft Components and the wide range of uses these will have for aircraft in the future.
X-Aerodynamics founder, Cameron Garner, explained the process of creating a virtual model of an aircraft that can then be used in simulations to provide accurate data for companies trialing new aircraft designs.
The potential of using Solar Powered UAVs to capture high resolution, low cost, aerial images on a frequent basis, was explained by Mark Rocket, CEO of Kea Aerospace.
Colin and Freeman from Aeronavics, a drone company based in Timaru, informed the CPD attendees about their developments in the commercial drone space.
Seagliders are an exciting potential contender in the future of the New Zealand transport industry. Shah and John from Ocean Flyer presented their case for the REGENT Seagliders that they’re bringing to our shores in 2025.
The CPD sessions are held monthly. The team at Flight Structures are grateful to Hemi who has taken on this role and done an excellent job. If you are interested in attending or presenting at a future CPD session, feel free to email Hemi for more information
First Flight for Pacific Aerospace SuperPac XL501
It was an exciting day yesterday for Pacific Aerospace with the first flight of ZK-EPO - SuperPac XL501. There’s been a lot of hard work by many people to get to this point - the team at NZSkydive, the Flight Structures staff , and the CAANZ Certification and Airworthiness Group.
First Flight
ZK-EPO First landing
Design and Certification of ADS-B Out for the MOD and NZDF
Flight Structures is approaching the conclusion of a project with the Ministry of Defence and NZ Defence Force to design and certify a transponder system with ADS-B Out (Automatic Dependent Surveillance-Broadcast) capability for the A109LUH(NZ) Aircraft. ADS-B Out allows aircraft to broadcast their identification, position, altitude and velocity to other aircraft and Air Traffic Control.
Flight Structures were successful in their bid for the project in 2021, and the installation programme is taking place throughout 2022. The project included our engineers designing and providing all certification documents to the New Zealand Defence Authority for approval. It was the first time a CAANZ Approved, Part 146 organisation, has been used for a project of this nature.
Thank you to the following key Flight Structures staff: Duncan Wollen, Adrian Dalton, Hemi Jones, Clyde James, Ted McCullough and Brett Purchase.
Photo is sourced from: https://www.nzdf.mil.nz/nzdf/our-equipment/aircraft/a109-light-utility-helicopter
BNZ Corporate Challenge 2022
Flight Structures bravely entered two teams in the BNZ Corporate Challenge in 2022 at the Grassroots Velodrome - doing any event and committing to it in the age of Covid takes courage. We entered an experienced team in the Cambridge Pursuit, and a team of new velodrome riders in the Italian Pursuit. Flight Structures were joined by three staff from Pacific Aerospace in this team event.
In the end we did have a couple of staff unable to ride due to sickness, so our reserve rider was busy, and another rider had to double up and race in both teams.
In the end we ended up with a 5th and a 6th placing, and to my eye, we had the best looking team in the sharpest most 2022 uniforms.
Well done to all the team - Hemi, Adam, Jon, Lucas, Scott, Steve, Clyde and Ray.
Pacific Aerospace Gain Part 146 Certificate
Yesterday Flight Structures were delighted to receive the Pacific Aerospace Part 146, Design Organisation Certificate from the Civil Aviation Authority of New Zealand. Pacific Aerospace, Flight Structures and the CAANZ have been working on this through the last few months, including through lockdowns in the Waikato region.
Jon Kerr is the Chief Designer for Pacific Aerospace, Kyle Knight is the Programme Manager , and they are supported by a team from Flight Structures including Murray McGregor, Dave Roberts, Daniel Mossman, Basil Eldo, Hemi Jones and Adam Jones.
Regaining the Certificate is a major milestone in the progress by the new owners towards completing the Super PAC aircraft which the team are working on.
Merlin Labs Certification Milestone.
There has been an exciting announcement from Merlin Labs today, with a key step towards certification achieved with CAANZ (the Civil Aviation Authority of New Zealand). Flight Structures has been partnering with Merlin Labs as their Part 146 Organisation, with Daniel Mossman and Jon Kerr taking the lead for the Flight Structures part. Flight Structures has enjoyed working at the leading edge of certification on an autonomous flight project and we look forward to future stages.
Please read the linked article below for more information.
Flight Structures has Safety Management System approved....
Flight Structures is proud to announce that our system for Safety Management was approved last week. We were scheduled to have our on-site audit in April 2020 but that was delayed one year to April 2021 due to the Covid19 pandemic. We were pleased to gain this acceptance with no findings.
The advantage of the delay meant that the SMS has become embedded in our operation and culture. We are also pleased that Matthew Tighe was accepted as a Senior Person within our organisation, with responsibility for Quality and Safety matters across the organisation.
It is an important year for us, with our CAANZ 146 and 148 Certificates being up for renewal in 2021. We have passed stage one of this renewal (onsite audits of our facility and work packages), with no findings in either the design or manufacturing organisation.
Kudos needs to go to the whole team who have worked very hard to ensure we passed these important milestones, but in particular to our three Senior Persons under CAANZ, CEO and Delegate Jon Kerr, Delegate Duncan Wollen, Prototype and Manufacturing Manager Brett Purchase, and Quality and Safety Manager Matthew Tighe, who pulled it all together.
Flight Structures announces ongoing relationship with Pacific Aerospace.
Flight Structures has been selected to manage Pacific Aerospace’s Design Organisation. Flight Structures’ CEO Jon Kerr said “This is a fantastic opportunity to support and represent Pacific Aerospace (PAL) to CAANZ as they embark upon a rebuilding phase. Operators of and maintainers of PAL aircraft will be able to go to FSL for repairs and modifications and receive OEM level support. “
Flight Structures Ltd is a CAANZ Certificated Part 146 Design and Part 148 Manufacturing Organisation that started in 2003. With 17 staff including two delegates we have extensive experience working across agricultural, utility, aeromedical and General Aviation in NZ. We specialise in aircraft design, certification and manufacturing projects.
PAL has a proud history in the Waikato dating back to 1949 with aircraft operating across the world in agricultural, skydiving, utility and training roles. Their aircraft include the 750XL, E-350, Cresco, Fletcher and CT-4.
STC Approval for Super Air Cresco Air Conditioning System
Super Air STC for Air Conditioning System on Cresco
Flight Structures is extremely pleased to achieve a Supplemental Type Certificate approval for Super Air in 2020. STC 21/21E/1 allows for the installation air conditioning systems into Cresco aircraft. This design change improves pilot safety by enhancing the cockpit environment.
Duncan Wollen was the Design Delegation Holder and Flight Structures’ Project Manager who worked with the Civil Aviation Authority on this project. In addition, close collaboration with Robbie Williams, Maintenance Controller at Super Air ensured the project was completed prior to the upcoming summer. Hamilton is an excellent place for these types of certification and installation projects with Hamilton Aero Maintenance and Central Aero being close neighbours, enabling testing and installation to proceed smoothly.
