Using the latest in 3D design software, our engineers are able to quickly progress from a simple sketch to detailed 3D assemblies and drawings. We utilize CATIA V5 and SolidWorks to produce conceptual layouts, engineering drawings and numerical control definition. In most cases, we can import our customers existing design definition into our software and iterate the design in order to generate a finished product.
Mace Aviation can provide engineering support across all portions of the design process. From simple hand calculations for initial layout to detailed Finite Element Analysis for sizing a wing spar, we possess the engineering skills necessary to efficiently and safely engineer structures of all types.
Mace Aviation can perform a wide variety of analysis services ranging from simple hand calculations to detailed Finite Element Analysis (FEA) of an entire aircraft structure. We use industry standard simulation software such as Hypermesh, FEMAP and NASTRAN for structural analysis. The design and analysis software utilized by Mace Aviation allows us to quickly iterate between 3D design and structural sizing which provides an efficient path to customer requirements.
Mace Aviation can design and fabricate composite and metal tools for all types of manufacturing processes. We can build tools that range from low-cost foam tools for prototype production to more expensive high-temperature tools designed for mass production. We work one-on-one with our clients to develop high-quality solutions based on their individual time and resources.
Mace Aviation specializes in the fabrication and assembly of composite and metallic aircraft structures. We perform a variety of composite manufacturing processes that include wet layup, prepreg layup, VARTM and bladder molding of fiberglass and carbon fiber parts. While our internal machining capability is always growing, we work with a number of highly qualified machine shops that can supplement our capabilities. Mace Aviation has separate facilities that are dedicated to composite and metallic fabrication and assembly. Our composite manufacturing facility has areas dedicated to ply kitting, layup, curing and assembly. Our metal fabrication facility is equally equipped to fabricate aircraft grade parts and assemblies. Mace Aviation is currently pursuing ISO 9001 certification.
Most structures require proof testing to validate the design and analysis portion of a project. Our engineering staff can design test fixtures that will simulate real world operation prior to flight. Structural proof testing prior to use is a valuable exercise for validating the design but also provides an additional layer of safety prior to use. Our test fixtures and instrumentation allow us to measure force, stress, strain or deflection.
07. Flight Testing
Mace Aviation has performed a wide variety of flight test missions that range from initial check flights to firing weapons on military test ranges. Mace Aviation currently has a Bell 206, MD500E and several fixed wing aircraft available for flight testing. A typical test program involves modifying the aircraft to customer requirements, obtaining appropriate approvals, performing the flight tests and returning the aircraft to original condition. Because we use our own aircraft, we can outperform our competitors in schedule and cost.
Mace Aviation’s experience and capabilities make us uniquely suited to progress from a rough sketch to a functioning prototype in extremely short periods of time. By leveraging our composite and metal fabrication facilities, mockups and functioning prototypes can be constructed for a variety of purposes. Whether you come to us with a hand-drawn sketch or a fully dimensioned model, we can prototype it.
09. Reverse Engineering
Mace Aviation excels at reverse engineering parts or products that already exist but are lacking complete engineering definition. Whether the part is a small fairing or a complete aircraft, we can reverse engineer it. Depending on the level of accuracy required, tools that range from scales and micrometers to a laser interferometer can be used to extract geometry. Extracted geometry is imported into CATIA and resurfaced. 3D CAD models of the reverse engineered part can then be used to modify the existing design or be used to generate new tools for part build.
Mace Aviation has a broad range of experience with aircraft avionics, wiring harnesses and installation. Mace Aviation’s experience ranges from basic troubleshooting to 3D layout and fabrication of entire instrument panels and wiring harnesses. Contact Mace Aviation to find out how we can assist you with your project.