Engineering and Design

Overview

We believe that successful products are born from a deep understanding of the needs and aspirations of our customers. Out approach combines rigorous research, collaborative brainstorming, and iterative prototyping, ensuring that every design decision is informed by real-world insights.

Airborne Systems follows fielded products to ensure they provide maximum capability to the user. This is done throughout continuous education, training, and support in the field.

Systems engineering tools including integrated master schedule/integrated master plan, specification compliance, validation tracking, and risk assessment are utilized to ensure project success.

In addition to the development of internal specifications for fabric, parts and equipment, Airborne Systems engineering process also includes programmatic test plans, test reports, final verification matrices and reports.

Mechanical Design and Manufacturing

Airborne Systems mechanical design expertise includes design of mechanical parts and mechanisms, as well as design of pyrotechnic devices. These include metal fittings in the parachute structure, servo actuated devices, adaptive structures to interface with the customer vehicle, parachute compartmentation, and integration with pyrotechnic class controls and actuators. Airborne Systems engineers are expert in the mechanical design of these critical components.

Airborne Systems engineers work with a wide range of tools of stress analysis, including linear, non-linear and topology and topography optimization.

Control Systems

Whether for test, demonstration or production flight, Airborne Systems controllers integrate easily with the pyrotechnic and electro-mechanical class actuators that are common in recovery systems. Other Airborne Systems products have been space-qualified.

Airborne Systems controllers fly daily in aircraft spin and stall recovery systems for many customers. These systems control both pyrotechnic and servomotor devices. Built-in Test (BIT) systems have both enhanced flight test safety and reduced system maintenance between flights.

In addition, customers can count on Airborne Systems’ knowledge of recovery system controller design to support their own designs.

Systems Analysis

Multiple structural and dynamic simulation capabilities are integral part of the systems approach utilized by Airborne Systems to provide the best solution to our customer’s requirements.

Airborne Systems utlizes the Altair HyperWorks suit of engineering codes, and maintains numerous LS-DYNA licenses. Airborne Systems has pioneered the use of LS-DYNA to perform parachute Fluid Structure Interaction (FSI) simulations.

Fabric Design and Manufacturing

Fabric Design is central to all of our product development. Our engineers are experts in the design and specification of fabrics including broadcloth, tape, webbing, cords, ropes, and coated fabrics. Airborne Systems is also expert in the joining of all classes of fabrics to create efficient structures for these dynamic fabric-based parachute and inflatables systems.

Our Space and Recovery Systems engineers work with all modern fibers and constantly tracks emerging technologies in fibers, fabrics, film, scrims, and coatings. Airborne Systems is at the forefront of introducing new lightweight laminate materials into parachute systems.

Parachute Trajectory Modeling and Simulation

An extensive analysis capability exists within Airborne Systems to reliably predict parachute system performance. MIDAS (Multiple Independent Decelerator Analysis Simulation) is the Airborne Systems developed, industry leading, 6 DOF recovery system trajectory and loads analysis code. MIDAS is grounded in decades of parachute system testing and includes all of the higher order terms of parachute deployment and inflation including:

    • Time dependent parachute drag area, including highly nonlinear responses
    • Parachute apparent mass growth during inflation
    • Cargo/payload aerodynamic terms
    • Integration with Global Reference Atmospheric Models (GRAMs) permitting assessment of location specific atmospheric and wind conditions
    • Integrated Monte Carlo scripts for system stochastic assessments

Program Management

Our Space and Recovery Systems team includes experienced project managers who prepare detailed monthly reports of cost, schedule, and technical performance. We utilize schedule management tools such as MS Project to develop and integrated master schedule and then monitor and track progress. As required, Airborne Systems can provide program control and reporting using an earned value management system.

Airborne Systems uses the Syspro management information system, which provides timely and accurate cost tracking and reporting, as well as parts/inventory status and purchasing functions.

In addition to tracking against the agreed contract cost, the Airborne Systems program manager regularly reassesses progress against each work breakdown schedule (WBS) item and compares the expenditures against the work completed. This data is prevented via estimate to complete/estimate at complete reports. These data, when combined with the progress tracking and the integrated master schedule allows earned value to be assessed and reported.

Airborne Systems has an established supplier base to support its engineering and large-scale manufacturing operations. All suppliers of parts and materials are assessed against Airborne Systems requirements before being entered onto an approved vendors list.

Configuration Management

Airborne Systems has a well-established Configuration Management program, documenting over 100 years of parachute design and manufacture. Configuration control is used to manage all changes to design and documentation throughout the life of a product, from the initial release of sketches for sample manufacture to the final Technical Data Package.