From concept to compliance: engineering and certifying helicopter components

This master's thesis explores the complete process of certification, testing, design, and manufacturing of a component intended for installation on a helicopter. The research begins with an in-depth analysis of the regulatory framework governing aerospace components, focusing on certification standards set by aviation authorities such as the European Union Aviation Safety Agency (EASA). Following the regulatory overview, the thesis delves into the design phase, detailing the application of advanced engineering principles and computer-aided design (CAD) tools to develop a robust and efficient component - more specifically, a Tablet Holder to be installed on a AS350 B3 helicopter. Emphasis is placed on ensuring the design meets both functional requirements and stringent safety standards. Subsequently, the analysis phase is detailed, encompassing two tools that are commonly used in the aeronautical industry, namely Finite Element Analysis/Method (FEA/FEM) and test bench. Both numerical examples for the Finite Element Analysis and a theoretical description of the sensors used in a test bench and the data acquisition are provided. The manufacturing phase is then scrutinized, highlighting the selection of materials and production techniques suitable for aerospace applications. Key manufacturing processes are described, including quality control measures to ensure the component's reliability and performance. Finally, a complete list of the documents required in order to be compliant with the most recent certification standards is provided. Such documents are the summarisation of the aforementioned steps, as they represent the results and output of a Design Organization Approval (DOA).