UK CAA Part 21J aviation design & Part 21 G production

Mechanical design & rapid prototyping

Our UK CAA Part 21J team are well versed in all aspects of the mechanical design process particularly in the field of rapid prototyping and integrated CAD simulation. This area is of particular value in the design process during the final stages of determining the final specifications / requirement definition. This can, depending on the modification, remove the need for costly full cabin mock-ups and models which inherently have a low level of utility after this phase.
 

• 3D Design for Fabrication, machining & composites.
• Stress calculations, Damage Tolerance & Fatigue Analysis
• Rapid prototyping (3D printing)
• Integrated CAD simulation (Finite Element Analysis)

Electrical design including avionics and mission requirement modifications / upgrades

One of the largest elements of our work with clients is in updating or modifying electrical systems that are fundamental to either the airworthiness of the aircraft or enhance their relevance to changing mission criteria. In all cases our focus is how to cost effectively deliver the client’s mission but also protect / future proof the platform for ‘mission creep’ or predicted changes in air traffic control such as ADS-B Out or TCAS.

Of particular note are the changes in airborne connectivity and how aircraft are being equipped for higher speed data links. This is usually seen to be the domain of applications such as in-flight Wifi for the business aviation sector however it has greater applicability within the Air Ambulance community, with the flow of secure patient data between hospitals, paramedics, land and air services (you can find more on connectivity services here)

Typically the team will deliver the following systems:

• Avionic Cockpit Upgrades
• Flight Management Systems
• Camera Mounts
• Satcom Upgrades and data connectivity
• Flight Data Recorders
• Transponders, TAWS, TCAS
• Radar
• NAV-COMM
• Rad Alt

Mission systems and aircraft role enhancement

We possesses industry leading expertise in the development, integration and support of Intelligence, Surveillance and Reconnaissance (ISR) solutions (for more details see Mission Systems). Our specialist staff offer a full spectrum of design and production services from project inception through to delivery. Typical mission enhancement projects include:

• Integrated Systems
• Mission Consoles
• Tactical Radios
• E/O and I/R Optics
• Mission Computers
• Mapping Solutions
• NVG
• Flight Data Recorders

Interior design & modifications

From high-end business jet requirements to mission modifications for Air Ambulance, we provide a range of services for clients which include the full re-role of aircraft to refurbishments of seating.
 

• Interior upgrades (carpet, seating, cabinetry, upholstery, etc.)
• Air Ambulance modifications (cabinets, patient loading systems, storage systems, etc.
• Child seating systems
• Rapid prototyping

Refurbishment projects. Renewing the life of 37 year old Beechcraft King Air 200 seats

The solution to every problem doesn’t always require a new replacement.

After analysis of the cost benefit of new vs old the Part 21J Design team have just completed a B200 King Air Seat refurbishment project. The 37-year-old seats that had seen better days were stripped down to the frame, inspected, repaired and then rebuilt to the customers specification while addressing marginal weight saving gains.

The top images show the previous state of the seats showing everyone of their 37 years of service. Those below show the completed seat prior to being refitted back into the airframe.

UK CAA Part 21 G production services

In addition to our Part 21J design services we also provide P145 and P21G production offering a complete end-to-end solution within a single organisation. This assists our clients as they have one project management interface with full accountability from design, to production to the installation of the modification. Post installation, our clients also benefit from a global support structure that is ready and able to ensure your availability if maintained.

Part 21G services are as follows:

• Metal Fabrication
• Machined Parts
• Manufacture of Mechanical Assemblies
• Metal treatments
• Composite manufacture
• Composite Repairs
• Production of Cable Harnesses
• Manufacture of Electrical Assemblies
• Building SUB Assemblies
• Kitting
• Interior Panels
• Interior Trim
• EASA Form 1 Release

Part 21 J aviation design STC's for purchase

New Part 21 J design STC applications are being submitted on a regular basis, please contact the design office for further information. Our capability also includes the approval of existing avionics equipment and installations on aircraft.

For more information please arrange a call with one of our team.

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