• Design & Engineering

Aero Services delivers practical, certifiable design and engineering solutions that transform customer requirements into production-ready systems. Our approach is rooted in real-world manufacturing experience, ensuring designs are efficient, robust, and fit for purpose in demanding operating environments.

Design

We take a customer-centric approach to design, working closely with clients to translate ideas, constraints, and performance requirements into engineered solutions:

  • Customer-driven solutions – Turning customer-specific requirements into functional, real-world designs
    • Multi-industry experience – Proven capability across aviation, rail, automotive, defence, and industrial applications
  • Manufacturing-first philosophy – Designs developed for practicality, repeatability, and cost-efficiency
  • Africa-focused engineering – Solutions tailored for demanding operational, environmental, and economic conditions
  • In-house capability leverage – Designers utilise internal processes, tooling, and manufacturing methods
  • Local material optimisation – Preference for locally available raw materials where appropriate
  • Advanced design tools – Designs and drawings produced using the latest SolidWorks design and simulation packages

 

Engineering, Analysis & Validation

Our engineering team combines academic rigour with hands-on industry experience to deliver designs that perform reliably in service.

  • Highly skilled team – Postgraduate and graduate engineers supported by experienced draftsmen and designers
  • Robust structural analysis – Stress analysis using advanced FEA / FEM software, supported by traditional hand calculations

 

Test-Informed Engineering Approach

Where required, Aero Services uses physical testing as an integral part of the engineering process, generating real-world data to validate assumptions and refine Finite Element Models (FEM).

 

Test results are used to:

  • Validate material properties and laminate behaviour
  • Confirm boundary conditions and load assumptions
  • Improve confidence in predicted stresses, deflections, and failure margins

This closed-loop approach reduces programme risk, particularly for new laminate schedules, non-standard geometries, or demanding load cases.

 

Static Testing & Structural Validation

Structural Verification & Testing

Where safety, durability, or certification requirements demand it, Aero Services conducts static (and where applicable, dynamic) testing to verify structural integrity and performance. Static testing provides direct validation of real-world load cases and design assumptions.

 

End-to-End Testing Capability

Our testing capability includes:

  • Development of static test procedures
  • Design and manufacture of dedicated test jigs and fixtures
  • Execution of controlled load testing
  • Collection and interpretation of test data
  • Generation of comprehensive in-house test reports

Testing is performed in collaboration with approved external laboratories where required, with Aero Services defining the test scope and using the resulting data directly within internal FEM and engineering workflows.

 

Reverse Engineering & Interface Modelling

Reverse engineering forms a key pillar of our capability, enabling accurate integration into existing platforms:

  • High-precision reverse engineering using a 6-axis Romer arm, integrated with SolidWorks
  • Interface modelling expertise, including fuselages, seat tracks, mounting interfaces, envelope constraints, and legacy structures
  • Improved integration confidence, supporting first-time fit and system integration

Door panel made from self-extinguishing plastic

Interior Ducting