Design and production

In the course of designing and constructing of our aircrafts the structure and systems go through a multiple staged and multi-disciplinary safety control process in order to ensure the high level of safe operation. This process is based on the CS-23/FAR-23 International designer and constructor specifications, phasing the safety requirements during operation.

The tasks of the design and the construction of the aircraft are insured under continuous and parallel control through the use of Computer-Aided Engineering software (CAE). Based on an integrated engineering background from SolidWorks, the CAE system provides the means to thoroughly test various forms of safe working behaviour during virtual operation. It also examines the effects of different loads on mechanical structures, fluid dynamics, as well as kinetic system simulations.

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Environmental impacts such as temperature, irradiation and humidity, are also taken into account during the testing phases.

During the simulation phase, the adequacy of the results is defined in proportion to the safety factors of the CS-23/FAR-23 certification standards. The results of system simulations are directly related to the issue of production integration. When the results of the simulations are in accordance with the certification and when it shows a plausible result, -only in this case- the structural parts, units and production of the equipment is to be manufactured. Production processes are controlled by internal quality control systems that provide continuous supervision.

Compliance is based on the quality of continued validation and verification of the logically interdependent-production chain, with the aim of debugging and analysing after correction.

The essence of validation means that a given technological process can be included in the production system only if its results can be validated, which is why most production and manufacturing methods are introduced in laboratory experiments.

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This means that if the material properties, geometry, and function of the units being manufactured are virtually identical to the required tolerance, they will be subjected to mechanical analysis under laboratory conditions, the main purpose of which is the approval of the manufacturing process. All of our institutions performing lab tests are accredited.

The purpose of verification during production is to examine the realization of the certifical specifications, which is why we make sure to prove several consistent results during the production process. The first milestone is certifying the externalization process of the given technological phase, which aids confirm the environmental conditions of manufacturing, for example, the heat treatment temperature and the exact values of the vacuum pressure for the high-tech composites we produce.

The second milestone is the NDT (Non-Destructive Testing) test of the manufactured element, when we search for micro and macro-sized structural defects in the internal structure and platform. If an error is detected, the manufactured structural component cannot be used and is disposed. As it regards the absolutely adequate results of the manufacturing process, we conduct random sampling from the produced pieces in accordance with a predetermined mathematical random analysis method, during which we use crash tests to verify the adequacy of the structures.

After production, the aircraft is tested along the lines of a program that meets predefined certification bases.

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