Engineering Services

Avionics/Electrical Engineering Services:

AAC Engineering offers avionics and electrical systems project engineering services; both in the cabin and flight deck. Experience includes electrical design, installation and certification of new systems and components, system and component upgrades, reliability tracking, maintenance support and troubleshooting. Major aircraft projects supported include GPS installations, ATC System upgrades and installations, Interior and IFE reconfigurations and upgrades, Electrical Load Analysis (ELA), Aircraft Condition Monitoring System (ACMS) software modifications, Airworthiness Directive (AD) compliance projects, and many others. AAC Engineering has worked on many Supplemental Type Certificate (STC) aircraft modifications and is familiar with STC documentation and process. For more detailed information about AAC Engineering’s Avionics and Electrical Engineering Services, please visit

Computer Aided Engineering Services:

• 3D Computer-Aided Design (3D-CAD):

Using 3D CAD software, AAC Engineering will take your new product from concept to 3D model and a detailed 2D engineering drawing. With 3D solid modeling, design changes can be evaluated and optimized before prototypes are manufactured. This allows you to consider multiple design options before needing to commission potentially costly design prototypes. 2D Drawings are updated real-time as 3D models are changed, allowing rapid distribution of engineering drawings for review and approval.

• 3D Printed Models and Prototypes

With the advent of 3D Printing, or Additive Manufacturing, the possibilities for designing and prototyping have expanded tremendously. Our clients benefit from the use of 3D printing to put ideas into your hands – literally. In some cases, the 3D printed product is the final step. In others, the final production product necessitates a different manufacturing method.

• Finite Element Analysis (FEA)

Finite Element Analysis (FEA) is a fundamental component of the modern engineering design process. AAC has the capability to analyze both static and dynamic entities. FEA enables us to evaluate unique load cases to validate the structural integrity of multiple design options. Following is an example of an FEA application made by one of AAC Engineering’s Structural Engineers (during former employment)

• Dynamic Analysis (DA)

Much like FEA, Dynamic Analysis (DA) is an integral part of the design process for any product or assembly that experiences changes in loading during its use. Loading can vary because of the changing external forces that are applied, or due to the loading experienced from the linear and/or rotational motion that is designed into the product. Ultimately, a thorough DA helps refine the structural and dimensional requirements of the product, and helps to select the proper material. AAC has complete DA capabilities for new and existing products.

Maintenance Engineering Services

AAC Engineering applies engineering experience, methods and knowledge to properly maintain equipment and ensure efficient, economical, safe and reliable operation. Maintenance Engineering includes the analysis of maintenance programs, ease of maintenance and the investigation of maintenance deficiencies or failures to support high levels of reliability — or in other words, to get the most out of your product or project.

The team at AAC Engineering has experience participating in airline industry working groups for maintenance programs. These groups aim at not only ensuring proper maintenance for individual airlines, but to improve maintenance, safety, and reliability of the airline industry at large.

Project Management

AAC has experienced Engineers in Project Management. Effective Project Managers have the skills to provide the tools and techniques to motivate and enable the project team to execute the project effectively. Projects must be delivered within the constraints of time, scope and money. Experienced Project Managers are skilled at controlling all three of these constraints.

The Project Management process can be categorized into five phases:

• Initiating – Defining the project, securing necessary financial resources, and setting communication in place with stakeholders are all important aspects of initiating a project.

• Planning – Creating a detailed report with chain of events that need to happen throughout the project. This includes a timeline and clear communication with stakeholders about how the entire project in all its phases.

• Executing – The goal of this phase is to organize teams to get the work done efficiently and effectively so that the project stays on target. It is important at this phase to identify all areas of risk or concern and mitigate these, and to address any change requests brought forth by the team.

• Monitoring and Controlling – At this phase, the Project Management requires keeping an eye on team performance and reacting quickly and appropriately to emerging issues. This is essential for maintaining positive forward momentum. Keeping stakeholders up to date on progress and team performance with reports and on-going documentation helps ensure project success. Regular assessment of progress related to scope, benchmark goals, timeline, and budget helps to ensure that there are no unpleasant surprises.

• Closing – Finishing the project strong with all the details in place is important. Ensuring all documentation is complete and current, for example Engineering Change Orders etc, is essential to a successful project.

Reliability Engineering Services:

Parts fail – no matter how well designed a part is, eventually they fail. AAC Engineering can help you find reliability issues, and drive to solutions.

How many spare parts will I need? When will I need them? When should I plan on overhaul? Is my warranty period correct? Can I save some money on my preventive maintenance program? Have I over-designed my part?

Reliability Engineering can help you answer these questions and more.

Reliability is a key ingredient in any project.  Parts and processes are prone to failures – why?  While this is different for every situation, reliability engineering can help you understand when things are failing.  Understand what is going wrong.  Understand what preventive measures can be taken to increase reliability and ultimately increase customer satisfaction.

Do you feel like your company is overspending on preventive maintenance?  Maybe you are – we can evaluate the entire program.  We’ll help optimize maintenance that is best for your operation.

Does it seem like there are a lot of questions here?  Sure – RELIABILTY ENGINEERING can provide the answers!

Structures Engineering Services:

• AOG (Aircraft On Ground) Support, Structural Damage:

The team at AAC Engineering understands operators’ needs to keep their airplanes on-line and on- schedule. When airframe damage is found unexpectedly, engineered repair designs can greatly reduce repair time.
Important Note: Please contact us prior to your first AOG support to setup support agreements. This provides a major improvement in support times to ensure we are ready to immediately meet your AOG operational needs.

• Heavy Maintenance Support:

With MRO maintenance running nose to tail, and pressure to keep check-lines on schedule, the timely support of heavy maintenance is often nearly as critical as AOG situations. When damage is found during routine inspections, our structural engineers have the experience completing hundreds of repairs. For part 121 operators, the need to develop repairs which are readily analyzed to support damage-tolerance requirements is also essential.

• STC Design Support:
From new equipment installation, to interior configuration modifications, AAC Engineering is ready to support your STC structural needs where you’re at. Whether you need structural reports to supplement your design package, Damage Tolerance Analysis, or interface load reports, AAC Engineering has the tools and experience to help you receive STC certification.

• Fatigue and Damage Tolerance Analysis

With the issuance of the Aging Aircraft Safety Rule (AASR), and requirements of FAR Part 26 added in 2007, the need to complete Damage Tolerance Analysis for repairs and alterations has grown significantly. AAC provides support for customers that keeps the entire repair and alteration life cycle in mind – from design/installation, through airframe service life. Our staff is trained in the concepts of fatigue, fracture mechanics and damage tolerance in aerospace structures as well as analytical and numerical methods of fatigue and damage tolerance analysis.

Systems Engineering Services:

AAC Engineers are experienced with the development, manufacture, modification, maintenance program requirements, reliability improvements and overall project management of aviation mechanical/electrical systems. Following are details relating to each element of the engineering process related to systems:

• Development: Analysis and design of detail parts and assemblies.

• Manufacture: Research methods for producibility related / cost savings improvements.

• Modifications: Identify solutions and generate Engineering Orders to implement changes. This includes working with suppliers and OEM documents to implement specific modifications.

• Maintenance Programs: Developing a maintenance program that ensures the highest return on investment on the equipment. Frequently this involves analysis of OEM recommended maintenance program documents and optimizing a customer-specific program to maximize operator benefit.

• Reliability: Analysis of industry and customer unique reliability data to develop data driven reliability improvements. Corrective actions may come from OEM Service Bulletins, changes to the maintenance program, set up of specific shop overhaul times, or other remediation corresponding with root cause determination.

Technical Writing:

The team of Technical Writers at AAC Engineering is experienced working under the constraints of standardized writing requirements, and are familiar with ATA 100, S1000D and Customer-Specified Documentation Standards. Our writers generate and revise work instructions from various sources (e.g. Aircraft Maintenance Manuals (AMMs), Service Bulletins, Airworthiness Directives (ADs), Manufacturer Task Cards, etc.). We can create the deliverables using the Customer’s product (e.g. Info Trust (AMDS), Arbortext, etc.), or with popular word processing software (e.g. MS Word, Adobe Framemaker, etc.) and export to common formats (e.g. doc, pdf, xml, etc.). We can create and make revisions to user manuals, logic trees, trouble shooting manuals, illustrated parts manuals and process workflow documents. Our Technical Writers are also experienced with image editing tools such as Corel Draw and Adobe Photoshop to create and revise graphics.

All of our Technical Writers have FAA Airframe and Powerplant (A&P ) certificates and have worked as aircraft maintenance technicians with experience in Aircraft Maintenance, Electronic Wiring Interconnect Systems (EWIS), Special Federal Aviation Regulation 88 (SFAR88) programs and the implementation of these programs from a both a Mechanic’s and Maintenance Programs perspective. Two of our technical writers also have General Radiotelephone certificates and have worked as aircraft electricians.

Technical Services – Reliability/Troubleshooting:

AAC Engineering’s Technical Service Representative (TSR) serves our Clients by assisting with the direction of efforts for line and hangar maintenance technicians on out-of-service and repetitive problem aircraft. Technical support is provided to direct and train technicians on troubleshooting procedures and techniques. Our TSR often bridges the gap between engineering and line maintenance for fleet wide performance issues.

Typical analysis topics include:

• Developing advanced troubleshooting procedures and tooling.
• Managing a repetitive discrepancy monitoring program to track problem aircraft.
• Improving aircraft reliability through early intervention and “confirmed fixes”
• Providing technical support and guidance to maintenance operations and engineering depts.
• Reviewing and evaluating new test equipment and maintenance and troubleshooting procedures.

Technical Training:

When it comes to training your staff, make use of AAC Engineering’s experienced Engineers, Technical Writers and Technical Service Representative. Typical training customers could include line and hangar technicians, inspection personnel, managers, engineers, tech support personnel, and others. AAC Engineering commonly works with Clients to customize and tailor training courses to the the Client’s requirements. This could include classroom, on site, or on the job training; initial, recurrent, or enrichment type. Some examples of training courses offered include:

• Developing and delivering training courses on aircraft systems, avionics, and powerplant on Airbus A319/A320, A330 aircraft types.
• Aircraft familiarization courses / New aircraft introduction
• OEM documentation/drawing introduction & use
• Aircraft servicing training
• Central maintenance computer (CMC/CFDS) training
• Troubleshooting training