787 Test Stands
Aerospace / Defense
Project details
Test stand systems supporting Boeing 787 aircraft component testing.
Vortex Systems
Integrating & Manufacturing World-Class Test Systems for Aircraft Repair Stations on a Global Scale
About the firm
Vortex Systems is an Enfield, Connecticut engineering firm founded in 1996 that designs, builds, and modernizes aerospace test stands and control systems for production, overhaul, and repair environments worldwide. With approximately 100 installations in 7 countries, it supports hydraulic, pneumatic, electro-pneumatic, fuel, vibration, and environmental test requirements using LabVIEW-based software and SOLIDWORKS mechanical design. ISO 9001:2015 certified and ACM member.
- Established
- 1996
- Team
- Small
- Firm type
- Aerospace Engineering · Automation & Controls · Electrical Engineering · Mechanical Engineering · Software Engineering
Credentials
ISO 9001:2015
Capabilities
Test Stand Design & Build
Service websiteNew turn-key test stand design, integration, and commissioning for aerospace and defense components, from concept through customer acceptance.
- Hydraulic test stands
- Pneumatic and electro-pneumatic test stands
- Air cycle machine (ACM) test stands
- Hot/cold fuel testing systems
- Environmental chamber test systems
- Actuator testing systems
- Custom test solutions
Legacy Stand Modernization
Service websiteRefurbishing and upgrading antiquated test stands with modern controls, software, and documentation to restore performance and extend service life.
- Controls upgrades
- Software re-work and documentation updates
- Calibration of existing equipment
Mechanical Design
Service websiteComprehensive mechanical component sizing for valves, pumps, flowmeters, and thermal/vibration requirements; SOLIDWORKS-based 3D design and test cell layout.
- Component sizing analysis (valves, pumps, flowmeters)
- Custom test enclosures and cabinets
- 3D test cell layout and facility design
- Air farm and chilled water facility consulting
Electrical Design
Service websitePower and analog circuit design, custom signal conditioning, printed circuit board fabrication, and custom card cage development for torque motors, LVDTs, resolvers, and PWM solenoids.
- Power and analog circuit design
- Signal conditioning circuitry
- Printed circuit board (PCB) fabrication
- Custom card cage design
Software Development
Service websiteLabVIEW-based test control and data acquisition software with tiered password protection; operator training included with all deployments.
- LabVIEW test control software
- Data acquisition and logging
- Calibration simulation test boxes
- Operator and engineer training
Vibration Testing
Service websiteComponent vibration testing using a Spectral Dynamics SD20000 shaker system with Jaguar Vibration Control, covering random, swept sine, tracked resonance dwell, and classic shock profiles.
Fabrication
Service websiteCustom electrical harness fabrication, cabinet wiring, metal fabrication, and welding for precision aerospace assemblies.
- Electrical harness and cabinet wiring
- Metal fabrication and welding
Calibration Services
Service websitePrecision calibration of existing test equipment to industry standards, extending service life as a cost-effective alternative to replacement.
Industries
Aerospace · Defense · Aviation · Manufacturing
Projects
JSF (F-35) Rig
Aerospace / Defense
Project details
Test rig built for JSF / F-35 aircraft component qualification.
SCU-CRU Test Equipment
Aerospace / Defense
Project details
Supplemental Cooling Unit / Cargo Refrigeration Unit test systems for aircraft environmental control.
Fueldraulic Test Stand
Aerospace / Defense
Project details
High-pressure hydraulic and fuel system test stand for aircraft component certification.