DEFENCE​
ESAI
DEFENCE​

AEROSPACE

ESAI

Largest Non-captive Aerospace Resource Pool

Subsystem and Component MRO

Airbus Authorized Signatories

Passenger to Frieght Conversion

Electrical Wiring Harness

Primary & Secondary Structures

Interiors

Bombardier Diamond Supplier

Next-Gen In-Flight Entertainment

Objective

  • Capacitive touch-based passenger multimedia unit and seat-back display unit

Approach

  • Capacitive multi‑touch small‑form‑factor display
  • Development of Linux firmware and Android integration on SoC based on ARM core
  • Integration of peripherals into Android
  • Independent V&V for Linux and Android
  • Android CTS‑based product validation
  • Certified for commercial aviation standards
  • Awarded the best technical innovation at the Aviation industry conclave

Outcome

  • Enhanced Passenger Experience thru Modern UI/UX, Reduced Development & Integration Complexity, Future‑Ready Platform

Fuselage

Objective

  • Design, Development and Optimization of Composite Fuselage Structure

Approach

  • Concept design, feasibility studies, Detail Design, DFM, DFA, which includes Complete definition dossier, Preliminary sizing, stress analysis including F&DT
  • Certification of all the primary structural parts as per EASA requirements
  • Non conformity/ concessions – both design and stress assessment
  • Components: Skin, Stringer, Frames, Clips, System cutouts and Section Assembly

Outcome

  • Weight optimization through concurrent design.
  • Design improvement to reduce concessions and DQNs.
  • Minimized number of part variants to reduce tool & production cost.​

Electrical Wiring & Interconnection Systems

Objective

  • Design & Development of Aircraft Electrical 3D design

Approach

  • Aircraft Electrical Harness Concept & Detail Design 
  • 3D Harness Routing
  • Primary Support Bracket Design and Installation
  • Create Clash Report and Deviation report
  • Ground Lengths, Ground Locations and Compatibility check
  • Segregation and Separation compliance
  • Grounding and Bonding compliance
  • Harness Release Process in Enovia/PLM
  • Engineering Change Management

Outcome

  • Full life cycle of electrical system & harnesses – concept to manufacturing
  • Nose-to-tail of the aircraft – complete aircraft systems

Design to Build of Composite HT&VT

Objective

  • Design to Manufacturing Support of composite Horizontal Tail & Vertical Tail for an Aircraft

Approach

  • Design of Horizontal Tail, Vertical Tail & Rudder
  • Improvement of Structural Efficiency
  • Design Specifications to meet FAR25 standards
  • Optimization using Carbon Fibre Composites
  • Reconfiguration of Structural Arrangements
  • Bird strike requirements
  • Aero Elasticity Analysis
  • F&DT​
  • Study of Kinematics of Rudder & Horizontal Tail

Outcome

  • Achieved more than 30% Reduction in Weight
  • Achieved Reduction in Number of parts 
  • Usage of Co-Cured Co-Bonded Carbon Fibre Composites

Design and Sizing of A350-XWB-900/1000 Cargo Floor

Objective

  • Complete design and stress solutions for Cargo Door Surround (CDS) structure of S13/14.

Approach

  • Sizing of the CDS primary composite and metallic components as per OEM requirements
  • Providing design solution which meet the manufacturing and assembly requirements.
  • Providing stress justification report for all primary and secondary structures.
  • DFM drawings and CATIA models in VPM