Fliegen Works Inc. | Aeronautical Engineers – Portland, OR – USA

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Summary: Developed a certification plan for installation of Aerocet 5850 Twin Seaplane Floats on a Dehavilland DHC-2 Beaver Airplane.

Project Name: Aerocet Floats Installation on a DeHavilland DHC-2 Beaver Airplane

Client: Aerocet Inc.

Client Request: To receive a certification plan that would allow them to get an STC for installing Aerocet 5850 floats on a DeHavilland DHC-2 Beaver airplane.

Project Summary: The client designed new composite floats for installation on the DeHavilland DHC-2 Beaver airplane. They asked Fliegen Works to develop a certification plan and checklist to get this installation approved by the FAA. Fliegen Works also performed flight and landing structural loads analysis on the float attachments in order to certify the mounting of the new floats.

Results: Fliegen Works developed a compliance plan and checklist and developed a Maintenance Manual (MM), Instructions for Continued Airworthiness (ICA), and an Illustrated Parts Catalog (IPC). The installation has been approved for an STC.

FAA Approvals: STC for installation of Aerocet Floats on a DeHavilland DHC-2 Beaver airplane.

Beaver on Aerocet 5850 Floats front


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Summary: Developed a certification plan for installation of a Zeiss Aerial Survey Camera (ZASC) system in Cessna model 180, 210, and 310 airplanes, including installation of five major components: camera body, film magazine, camera mount, sight, and computing unit (TC-U).

Project Name: Structural Substantiation for Camera Equipment Installation STC.

Client: Bergman Photographic Services of Portland, Oregon

Client Request: To generate structural substantiation data and create documentation necessary to apply for multiple STCs for the installation of a Zeiss Aerial Survey Camera System (ZASC) on three aircraft: Cessna model 180, 210, and 310 airplanes.

Project Summary: The client wanted to install a Zeiss (TOP-15) camera on any of three aircraft: Cessna model 180, 210, and 310 airplanes. The camera body needed to be used with several different mounts and with several different film magazines, and the interchangeability of the camera equipment needed to be done in a timely manner. The client needed Fliegen Works to generate structural data that substantiated the installation, and they wanted Fliegen Works to create documentation that could be used to apply for multiple STCs related to this installation.

Results: Fliegen Works developed a structural substantiation plan for the camera on the three Cessna airplane models, and created documentation so that the required multiple STCs could be approved.

FAA Approvals: STC for installation of Aerial Survey Camera (ZASC) system in Cessna model 180, 210, and 310 airplanes.

Camera installation in Cessna 210

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Summary: Thrush S-2R Series Conversion to Walter Turbopropellers

Project Name: Thrush S-2R Series Conversion to Walter Turbopropellers

Client: Cascade Aircraft Conversions

Client Request:

Project Summary:  Fliegen Works Inc. provided structural engineering substantiation, detailed designing and analysis, and DER services for an STC based project to convert Thrush S-2R series aircraft to Walter M601D-11 and M601E-11 turbine engines.


FAA Approvals:

Thrush aircraft turbine conversion

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Summary: Reduced the weight of a hospital’s neonatal incubator transportation unit, lessened electrical power usage, and provided STCs for change in type design for Bell 430 Helicopter and Twin Commander 695 Airplane.

Project Name: Neonatal Transportation Unit Modification

Client: Emanuel Children’s Hospital of Portland, Oregon

Client Request: To reduce the overall assembly weight of the hospital’s neonatal transportation unit for a Bell 430 Helicopter and a Twin Commander 695 airplane.

Project Summary: Emanuel Children’s Hospital of Portland, Oregon, transports critically ill neonatal infants with their Bell 430 helicopter and Twin Commander 695 airplane in an incubator that attaches to a Lifeport, Incorporated click deck litter. Several staff members have suffered workplace back injuries as a result of the excessive weight of the entire assembly. The hospital asked Fliegen Works to modify the design to reduce the overall weight of the assembly and to get the system approved for operation in the Bell 430 helicopter.

Results: Fliegen Works replaced the oxygen shroud with mounted ventilator, patient monitor, and two E cylinders of the Lifeport ITM with lighter weight equipment. The new medical cylinder shroud houses two cylinders, has a new Broncotron mechanical high frequency ventilator, and new Crossvent regular ventilator with monitoring functions. The ProPaq patient monitor mounts to the new shroud with a lighter attachment. In addition to lightening the assembly, the ventilators use less electrical power than the original ventilators.

FAA Approvals: STC for change in type design for a Bell 430 Helicopter (ST02257AK) and a Twin Commander 695 Airplane (SA01620SE).

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Summary: Conversion of a CASA C-212 from the passenger only configuration, to a combined passenger and cargo configuration (Combi).

Project Name: CASA C-212 Combi Conversion

Client:  FS Air Service 

Client Request: Get an STC to modify the CASA C212 for carrying cargo with passengers in the same cabin with multiple configurations. 

Project Summary: Fliegen Works Inc. provided a certification plan, compliance checklist, structural substantiation, smoke testing, and DER services in support of an STC project to convert the CASA C-212 aircraft from the original passenger-only or cargo only configurations to a combined passenger and cargo configuration. The project included a novel approach of using fire containment blankets to segregate the cargo within the passenger compartment using data from the FAA tech center. This project required the design and installation of new emergency equipment for installation in the cabin as well as a thorough Aircraft Flight Manual Supplement (AFMS). Fliegen Works coordinated with the FAA to grant an Exemption to allow the use of building type smoke detectors for fire detection within the fire containment blankets. This project culminated in TIA for demonstration of smoke detection per 25.857 and ventilation per 25.831.  Fliegen Works built a smoke box per AC 25-9A appendix II, which generates a precise amount of smoke and is available for other projects. 

Results:  STC ST02257AK approved for change in type design.


CASA C212 Combi Conversion

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Summary: Design, prototype and production of camera mount and lowering system for Immersive camera.

Project Name: IMC 407 Immersive Camera Mount

Client: Immersive Media

Client Request: To design and build a system that would lower Immersive Media’s camera below an array of helicopters.  The camera must have a 360 degree clear view, and be able to lower and raise out of harms way on landing.

Project Summary: See Immersive Media Camera Mount for Bell 206 and Robinson R44 for more information.

Results: Fliegen Works has prototyped and designed a camera lowering system that can attach to most helicopter landing skids.  It is simple to install, failsafe, and provides a stable platform for the camera to have a full 360 degree view when lowered. Fliegen Works has completed certification after successful structural and flight tests.

FAA Approvals: STC approved for the Installation on the Bell 206, and the R44, PMA approval for manufacturing.

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Summary: Design and DER work to substantiate the installation of two bulkheads and cargo nets to restrain bucket cargo in a Cessna 206 aircraft.

Project Name: Structural Substantiation, Cessna U206F, Cargo Restraint System

Client: Troutdale Aircraft Services

Client Request: To design and analyze a system to restrain buckets of agricultural cargo in the passenger area of a Cessna 206 aircraft.

Project Summary: Structural substantiation of modifications made to a Cessna U206F by removal of the passenger seats and installation of cargo restraints, including a bulkhead behind the pilot, a short bulkhead between the pilot and former co-pilot seat, multiple seat tracks installed for attachment of cargo fittings, and a series of cargo barrier nets.  In order to tie down the cargo nets and provide structure for the nets and bulkheads, seat track was installed along the sides and to the ceiling.

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