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

CAT | Supplemental Type Certificate Projects (STC)

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Fliegen Works is working with Joel Wattum to produce an installation STC kit for the Cessna 170A, 170B, and basic 172 to install Aerocet 2200 twin seaplane floats. Recently we finished up the engineering and flight testing and now have FAA design approval by STC SA02400AK.  Joel is accepting orders.

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Summary:  Design and Manufacturing of redundant servo-tab for installation on DHC-3 Otter for Airworthiness Directive (AD).

Client: VAZAR

Client Request: The DHC-3 Otter had a history of failures in the elevator servo-tab bellcrank. VAZAR agreed to address this issue on their turbine conversion to increase safety of the aircraft and meet the newer 23.629 requirement of flutter free after a single failure. Volant Technica was asked to develop the fix for the servo tab.

Project Summary: Volant Technica, a precursor company to Fliegen Works, worked with the FAA to address this service difficulty and produced the design data, developed loads and a structural test proposal, then DER witnessed the structural test. We also wrote the flight test plan and helped with the issuance of the TIA. The STC is a method of compliance to AD 2004-05-01. Fliegen Works currently holds PMA for fabrication of the redundant servo tab; it includes a 2nd control rod and other modification to fix in-service failure problem.

Results: STC SA01059SE was granted to VAZAR (as American Aeromotives) and is licensed to Fliegen Works for European import auto repair under PMA PQ2380NM.

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Summary:  Rudder Tab certification

Project Name: Rudder Tab On A-1 Series Blimps

Client: American Blimp Company

Client Request:  The client requested a fix to balance the aerodynamic torque created by an installed Lightsign on the left side of the blimp’s envelope.

Project Summary: We did the preliminary sizing for a fixed rudder tab and worked with ABC on the detail design. Fliegen Works developed the aerodynamic loads, produced a structural test proposal and then DER witnessed the tests. The design of a fixed tab on a Rudder of ABC A-1 series airships was a challenge since a number of engineering estimations were made. From minimal available blimp flight and aerodynamic data and old NACA data an analysis was performed to design a fixed rudder tab that biased the rudder to compensate for the unsymmetrical drag on the airship due to the Lightsign on one side of the airship. This was a major change to the type design by the type certificate holder.

Results: Successful flight testing, installation and approval of rudder tab on A-1 series blimp. Pilot force required to maintain straight flight reduced to acceptable levels. Rather than complex CFD, a simple method combined with a little guesswork was applied. Minimal time and cost was required to produce the required results in this manner.

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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.

Results:

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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