Engineering

Thinking of everything, implementing the best ideas

The 'What' comes from our customers - we take care of the 'How'. When it comes to engineering, weight and functionality are key parameters that are just as important as costs and deadlines. The objective is to always provide the best turnkey solution for efficient production. Customers can rely on FACC achieving this goal because we reduce development times by means of concurrent engineering and take customer orientation and proximity quite literally - our international branch offices are able to support and assist our customers everywhere on site.

Our service chain

Design & Analysis.

We prepare the basic engineering specifications in line with the relevant product requirements in cooperation with our customers.

Based on the mentioned product requirements, FACC's engineers, in cooperation with their customers, elaborate the technical specifications. Together with the customers and at their sites, FACC's specialists prepare technical concepts in the so-called joint definition phases. In several design quality gates, the design is specified down to the smallest detail. Based on comprehensive strength analyses, FACC's stress engineers assure the static strength and fatigue requirements of the relevant aircraft components. The Design Office translates these development activities into engineering documents (drawings and parts lists) for their use in production.

Material & Process Engineering.

We optimize materials and processes to achieve maximum process reliability and quality.

Material and process engineers optimize materials and processes with a view to achieving the highest process reliability and quality. They are involved in development projects and provide support for the ongoing series production.In addition, these experts provide advice to other FACC departments in matters of process engineering. They also deliver support for internal and external process audits.

Tool Design.

We develop our own tools and processing programs for cost-optimized manufacturing in line with the applicable requirements. The Tool Design unit develops special-purpose fixtures, production tools, and machining programs required for the manufacturing process. The result is CAD drawings and CAM programs used to numerically control the manufacturing machinery. Each main manufacturing step is carried out by a specific tool or fixture adapted to the component. The three main production steps for composite components covered in tool design are:

lay up and curing of the component
milling and drilling of the component
positioning several components referenced to each other and fastening them in order to assemble a complete aircraft component

Forming a link between product development and manufacturing, the Tool Design unit is to a significant extent responsible for the cost-efficient production of components in line with the relevant requirements.

Q-Engineering.

We ensure that all drafts result in products that can be manufactured cost-efficiently.

This subunit of the Quality Management function monitors entirely new and previously launched products from a quality perspective. At the beginning of a project, interfaces, communication workflows, and formalities are defined together with the customer. As the project progresses, the Quality Engineering unit defines and monitors the conformity of the developed products with their design documentation and conducts first article inspections. In addition, the team, in close cooperation with in-house departments and the final customer, coordinates and is in charge of any process improvements and corrective actions.

Testing.

Thoroughly analyzing and testing all component structures is an indispensable certification requirement for us. Structural tests are indispensable for the development and certification of components. They verify the stress engineering methods used for the strength analysis in order to ensure the efficient and safe use in subsequent in-flight operations.The test engineers analyze and test complete fiber composite aircraft structures, subsystems, and individual components for fatigue and static strength. In this connection, impacts (e.g. bird strike), temperature, and humidity are taken in consideration, as are manufacturing defects or delaminations. Based on the test concepts, suitable test equipment and systems are developed.The preparation of the measuring equipment for the test station and the final analysis of the measuring results complete the core expertise "Component and certification tests" and include support documentation. These documents are provided to customers and aviation authorities (FAA, EASA).

Integrated Logistics Support.

We integrate and ensure all logistical activities over the entire lifecycle of an aircraft (e.g. technical publications, maintenance task analyses, etc.).

The ILS, and the logistics support analyses (LSA/RAMS) in particular, decisively influence the availability and life cycle costs of an aircraft and its components. Therefore, the ILS contributes significantly to a product's success in the market. FACC's integrated logistics support begins with the concept phase and ends only with the decommissioning of the aircraft and/or its components.

Engineering Services.

We offer engineering IT and software tools, providing the required data as well as software trainings and updates.

Within FACC, the Engineering Services unit is in charge of the large number of software tools used and the computer-assisted processes in the engineering environment. In addition, services such as data transfer, document storage, document distribution, material master creation, and the creation of standard components (3D models) are provided. The support for software tools covers all steps from procurement, installation, training, and updating to individual user support. The engineering processes are defined in cooperation with the Engineering unit, mapped in SAP PLM, trained, and supported.