Aviation Engineering

we are shaping the future

APUS is an EASA certified Design Organisation that offers high standard aviation engineering services. Main topics of our development are innovative aviation propulsion systems, aeromechanical design, structural design, CAD and certification of aviation systems.
In addition, our profile includes industrial organization services as well as flight services and miscellaneous services in aviation.

Aviation Engineering is our main business domain. Our team is working on the complete scope of aircraft development. We provide an extremely professional engineering service, from the first idea of a new air vehicle including drafting, designing, testing, certifying, all the way up to prototyping. We predominantly consider ourselves as a subcontractor to aircraft manufacturers and aviation service providers.

We offer comprehensive flight services as well as support to existing providers to cover capacity peaks. With our experienced team and partners we are able to cover sensing missions and flight testing campaigns. Our team comprises experienced flight test engineers and test pilots with backgrounds spanning the full range from experimental to certification flight tests for all categories of CS23 aircraft and lower categories.

Fiber Reinforced Plastics (FRP)

Composite structures are the dominant technology today when it comes to aircraft construction. Any desired spherical geometry can be produced in this way. In addition, high-strength and high-rigidity structures can be produced with carbon fibres. 

20220601_Apus_12

APUS’ scope:

  • Analytical dimensioning
  • FE-simulations (ANSYS)
  • High tensile, high module fibres 
  • Parts and assembly design
  • Fatigue analysis
  • Hand lamination, resin transfer moulding (RTM) 
  • High temperature structures
  • Testing
03
02
01

Flight mechanics and performance

Every aircraft concept includes an analysis of the flight mechanics and performance. This allows an assessment of the extent to which the concept can meet the requirements or what effect an optimization of the aerodynamics or the structural mass has.

CFD_Image5

APUS’ scope:

  • Flight mechanics
  • Aerodynamic optimization
  • CFD analysis
  • Load assumptions
  • Performance analysis 

Electric / hydrogen powertrain

The greatest optimization potential of today’s aircraft lies in improving its propulsion system. With the great pressure to act to reduce emissions in aviation, the electrification of aircraft is becoming increasingly important. APUS has done pioneering work in this area in recent years and offers you the experience it has gained.

DSC_9323

APUS’ scope:

  • Concepting of hybrid electric powertrains
  • Selection of single components
  • Analysis of energy flow and optimization
  • Certificiation roadmap, certification programs
  • Failure hazard analysis 
  • Testing
  • Integration
  • Integration of balance of plant components
  • Power optimization
  • High altitude optimization
  • Thermal management systems
DSC_9320

Avionics

The nervous system of an aircraft, including that of a human rated aircraft, is the avionics. Wiring harnesses pass information between pilots and technical aggregates. Precise navigation and communication devices establish the radio connection to the ground or to orbit. Different radio waves must not interfere with each other. The systems have to meet high requirements in terms of vibration, temperature and humidity easily and at the same time reliably.

FEM_Pilot Panel

APUS’ scope:

  • Wiring Diagrams (Software: VeSys Design)
  • Printed circuit board layout
  • Harness design and production
  • Mechanical and electrical integration of avionic components
  • Failure hazard analysis 
  • Testing
Pilot Panel CAD
Pilot_Panel_workshop
Cockpit_V4
Platine CAD
Platine_6

Mechanical Engineering

The most classic engineering discipline is mechanical engineering. Our designers have a wealth of experience in the construction of mechanical components.

APUS’ scope:

  • Drafting and modelling
  • Design methodology and design organization
  • Structural analysis
  • Kinematic systems
  • Safety analysis
  • Documentation (drawings, part lists, specifications)
  • Software: SIEMENS NX
P00-002918-00_Tension_Regulator_CAD
TR Prototype

CNC milled structures

With our inhouse CNC centres we can produce any kind of milled solid part. The independence from long supply chains allows rapid prototyping and fast iteration of your designs.

Mold_1
Mold_side

APUS’ scope:

  • CNC-milling, foams, aluminium, steel
  • Composite prototype parts
Mold_top
Mold_2
Fräser

Welded metal structures

Alongside timber construction, steel construction is the oldest technology in aircraft construction. Even today, steel constructions still have a number of advantages. For example, point loads can be passed through better. In addition, the calculation and manufacture of such structures is very predictable and weight assumptions are much mor precise.

FE 2
Halle2
DSC_9305

APUS’ scope:

  • Analytical dimensioning
  • FE-simulations (ANSYS)
  • Systems design (control systems, hydraulic systems, gear systems)
  • Fatigue analysis
  • Prototype welding (Part 21 certified)
  • Testing (digital and physical)
DSC_9336

Tools and Jigs

A precise mold is the basis for every composite part. Our mold construction department manufactures all types of laminating molds with high surface quality. The very experienced prototyping staff supports your engineers with optimization proposals for your tools. 

prototyping-1

APUS’ scope:

  • Design and documentation
  • Inhouse CNC milling
  • Tools up to 10 m length
  • Carrying structure
  • Positioning references and jigs
  • Production optimization

Flight Testing

We have extensive experience in experimental and certification flight testing of fixed wing aircraft.

With our own data acquisition equipment and in-house pilots, we are prepared for any upcoming flight test task, from single test points via systems certification to a complete certification campaign.

Testing_1

APUS’ scope:

  • Certification programs 
  • Certification consultancy
  • Compliance reports
  • Compliance summary
  • Main experiences with certification processes of EASA and FAA
Testing_2

Certification

Every aircraft that is operated in controlled airspace requires a permit. This ensures safety and reliability. For an aviation system to be approved, certain rules must be taken into account in the design process. The system must also correspond to certain certification standards in its properties. It makes sense to involve approval specialists such as APUS in the design process from the beginning to avoid unnecessary iterations. APUS achieved several type certificates or supplementary type certificates together with its customers.

EASA

APUS’ scope:

  • Certification programs 
  • Certification consultancy
  • Compliance reports
  • Compliance summary
  • Main experiences with certification processes of EASA and FAA
certificate
Design organisation 
approval
certificate

EN

9100

Aerospace quality
standard
certificate

EASA

21G

Production organisation 
approval