November 22nd 2010
FAA approval of BCI facility and PMA Quality System
Customer-Focused
proven processes
YOUR DESIGN PARTNER
At Blackhawk Composites, we consider you our partner. When you come to us requesting solutions to boost your aircraft’s performance, strength, and payload, we partner with you every step of the way, from the first conversation through final FAA approval of your new part.
Our full-service capabilities allow us to perform all of the following, in-house:
Create full CAD for your part
Build the required tooling
Produce a rapid prototype
Refine designs
Fabricate your part in-house
Refine designs
Fabricate your part in-house
Perform finish work
Test the part
Assist with FAA, EASA, and other regulatory approvals
PARTNERING WITH BLACKHAWK
Producing Your Part
At the beginning of the process, Blackhawk Composites’ engineering team works with you on a successful design. Whether you’ve come with a problem you want solved, a napkin drawing, or a full set of designs, we’ll review your needs and prepare a proposal, complete with recommendations for the best way to achieve your goal on your budget and timeline. In many cases, it is not uncommon for us to go from a design idea to a complete solution in only a few weeks.
Once you approve your design and quote for production, a purchase order is created to begin work. Your team at Blackhawk Composites will manage all aspects of production, from design review, tooling, and prototype to fabricating, finishing, testing, and assisting with all required regulatory approvals.
CUSTOMER INTERFACE
Throughout your journey with Blackhawk Composites, you will have a dedicated project manager to support you and your project. Your project manager works with the Blackhawk team to ensure your project meets your quality expectations and is on schedule, all while providing you with daily updates on progress and estimated delivery. Your project manager will also oversee the production of your part, performing a number of tasks, including ensuring:
- The cross functional team’s review at the RFQ stage assures capability, capacity, and understanding of your requirements
- Develop prints and specs are produced to accompany your CAD
- Pre-approved rework procedures for specified conformance issues are established and followed
- Management of the NCR process
- Management of the ECR process for part or process changes
Case Study
Composite Solutions for Improved Performance
When certifying an engine upgrade solution for the Cessna Caravan 208B, Blackhawk Performance Upgrades turned to Blackhawk Composites to engineer and manufacture a new composite cowling to accommodate the upgraded aircraft’s larger, more powerful engine and dual port exhaust. The improved cowling design significantly reduces installation losses and improves inlet efficiency.
In full production today, the cowling is part of a complete performance solution increasing Caravan capabilities and helping operators do more and earn more. This industry success story is a model for how innovative composite use can improve legacy products while meeting market needs.
PROJECT DETAILS
- 54 individually molded components and 21 assemblies, adhesive bonded and mechanically fastened
- The carbon/epoxy composite materials passed 16 different tests, using five samples each, for a total of 80 test conditions
CERTIFICATION TIMELINE
THE BLACKHAWK ADVANTAGE
Blackhawk Composites utilizes highly experienced composites engineers, technicians, and leadership with the latest techniques and technology to develop aerospace-grade composite parts and assemblies. Our full in-house services, centrally located for inexpensive shipment, offer considerable cost-savings and efficiency, while our open and transparent communication strengthens customer trust and confidence. Blackhawk Composites is your cost-effective, time-saving partner for performance enhancing solutions.