Avenger Aerospace Solutions, Inc.

Structural design and analysis for metallic and composite airframe structures from prototyping and preliminary sizing through final design and structural substantiation.

• Detail Part & Assembly Drawings

  Detail part drawings in 2D or 3D electronic dataset format, and assembly and installation drawings with thorough installation instructions. Covers primary structure (wing, fuselage), secondary structure, and interiors. Supports FAA approval to the required certification basis.

• Static Strength Analysis

  Classical and FEM-based static stress analysis for a wide variety of aircraft structures, with DER certification for FAR Part 23, 25, and 26 compliance.

• Structural Loads Analysis

  Aircraft structural loads analysis for aerodynamic, inertial, and dynamic applied loads using Avenger BoxBeam code and MSC/Nastran.

• Composites Analysis

  Ply-by-ply analysis of composite structures, bonded and bolted-bonded joint analysis, interlaminar shear, and failure index using MSC/Nastran and laminate codes.

• Structural Test Plans

  Development and technical review of structural test plans at coupon, component, and aircraft levels, including constant amplitude and flight-by-flight loading and data reduction using nCode software.

Fatigue, damage tolerance, and crack growth analysis using state-of-the-art methods, including its own FAA-approved Methods Manual, to remove conservatism and accelerate certification.

• Safe Life Analysis

  S-N material data and test correlation, Palmgren-Minor and load-interaction fatigue damage accumulation, and stress severity factor generation.

• Damage Tolerance & Durability Analysis

  Crack growth analysis using linear elastic fracture mechanics, derivation of stress intensity factor solutions, flight-by-flight stress spectra generation, and establishment of inspection intervals for FAA SSID or USAF FSMP.

• Residual Strength Analysis

  Determination of limit load-carrying capacity of structure containing varying crack lengths or levels of damage.

• Fail Safe Analysis

  Failed member assumptions, redistribution of internal loads, and static strength analysis for fail-safe structural verification.

• Aging Aircraft Structural Integrity Programs

  Structural life assurance programs for aging commercial and military fleets addressing FAA aging safety rules, WFD requirements (FAR 25.571, AC 91-56, Part 26), and USAF AFGS-87221.

Structural liaison and inspection program development supporting maintenance activity, continued airworthiness, and FAA compliance for aircraft operators and MRO providers.

• Structural Liaison Support

  MRB, ECP, and O&A support; non-standard repair design and analysis; standard repair manual generation; compliance with ACs, ADs, and SSIDs; on-site repair design and installation support.

• Inspection Program Development

  Development of structural inspection criteria, damage tolerance-based inspection thresholds and repeat frequencies, visual and NDT inspection procedures, and full airframe inspection programs for FAR 25.1529 and Part 26 compliance.

• NDT Procedures & Calibration Standards

  Design and manufacture of NDT calibration standards, NDT Level 3 approval of procedures, and prototyping of inspection procedures tailored to customer requirements.

• Fleet Data Tracking & Analysis

  Operational usage data acquisition, evaluation, and application using nCode software to substantiate structural integrity, update structural life status, and support force structure planning.

DER and DAR support for major alterations and repairs, Type Certificates, and Supplemental Type Certificates under FAR Parts 23, 25, and 26, for both individual certification approvals and full STC product service.

FAA-regulated parts manufacturing and reverse engineering combining aerospace technical services with manufacturing capability for timely, cost-effective solutions.

• PMA Parts Manufacturing

  Manufacturing of production parts under FAA Parts Manufacturing Authority (PMA) for sustained aircraft support.

• Repair Parts Manufacturing

  One-off repair part manufacturing for owner/operator support, including one-time complicated repairs and part modifications.

• Reverse Engineering & Part Replication

  Reverse design and manufacture of legacy or overpriced OEM parts, leveraging 3D modeling and rapid prototyping partnerships for fit verification.

Management support for aerospace engineering, certification, and manufacturing programs.