Summary: Designing custom aircraft interiors is both challenging and rewarding. A lot of science goes into it, ensuring that each interior functions as intended while providing the necessary safety and comfort occupants require.
Designing an aircraft interior is a sophisticated balancing act. We need to account for everything from physics to human physiology and advanced material science. They all intersect in that space where passengers and crew live and work during flights.
We specialize in aircraft interiors for missions that are not well served by factory interiors. From high-stakes medevac missions to keeping world leaders and VIPs safe and comfortable in flight, our task is to create interiors that are far more than just a selection of seats and panels. Our interiors need to be engineered to maximize both passenger safety and mission success.
Material Science: The Foundation of Safety
The foundation of a safe and comfortable aircraft interior is material science. Every ounce of material must meet or exceed stringent regulatory requirements. At the same time, materials also need to be functional. The material science we employ rests on three core principles: weight, flame retardancy, and durability.
1. Weight Management
Strength-to-weight ratios are important, given that weight is the enemy in flight. The lighter an aircraft is, the greater its fuel efficiency and payload capacity. But structural integrity cannot be sacrificed just to reduce weight.
We minimize weight without sacrificing strength by using composites. Carbon fiber-reinforced polymers (CFRPs) and aramid fiber products, like Kevlar, are key components in our design and manufacturing. Both offer the structural integrity of steel at a fraction of the weight cost.
2. Flame Retardancy
In terms of fire retardancy, we must maintain strict compliance with Fire, Smoke, and Toxicity (FST) requirements. Every material we choose for an aircraft interior must be both self-extinguishing and capable of minimizing smoke and toxic fumes in the event of a fire.
To that end, every material undergoes a variety of burning tests. Some materials utilized in larger aircraft must be further tested for heat release for the purposes of ensuring safe emergency egress.
Engineering for The Human Factor
Safety is always the top priority. Yet we still need to engineer aircraft interiors to account for the human factor. Think ergonomics. In flight, it is more than keeping passengers comfortable. We are also tasked with minimizing cognitive load while maximizing physical endurance.
Imagine a surgeon performing a life-saving procedure in a moving helicopter. Imagine a corporate executive spending an entire 10-hour flight working at a desk. In both situations, design must support the human body. This forces us to come up with mission-specific layouts. Here are two examples:
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Medevac Helicopters – Medevac missions demand aircraft interiors capable of supporting life-saving equipment and procedures during flight. We use 3D modeling to ensure that everything is within reach so that crew members do not have to struggle as they care for patients.
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VIP and Corporate – An ergonomic design for a VIP or corporate aircraft almost always includes dynamic seating and acoustic comfort features. Dynamic seating can be rearranged to accommodate different layouts, while acoustic comfort is achieved through sound-dampening technologies.
At the conclusion of every flight, passengers and crew members should feel a minimal amount of fatigue. They need to hit the ground running. How we incorporate ergonomics into our aircraft interiors has a direct impact on whether they do so.
Structural Integrity and Crashworthiness
Passengers and crew members know good ergonomics when they experience it. Yet in the background are materials and design features built-in for structural integrity and crashworthiness. In essence, every aircraft's interior is part of a larger safety cage designed to keep passengers safe during hard landings and turbulence.
For example, seating and equipment mounts are engineered to withstand considerable G-forces. We might be working on a medevac helicopter that needs to be rated for impacts of up to 20G. Achieving such a high rating would require:
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Specialized Seating – Energy-attenuating seats designed to deform in a controlled manner absorb energy on impact. This protects occupants from injury.
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Precision Mounts – Precision mounts, utilizing customized track systems and locking mechanisms, guarantee that equipment and cabinetry remain secure during turbulence or high-stress maneuvers.
Turbulence is a normal part of flight. We must design for it. Likewise, we hope none of the aircraft we work on is ever involved in a crash. But our design must account for that possibility. Our interiors must possess the structural integrity to keep occupants safe, no matter what happens.
Controlling the Interior Environment
Another essential design element is environmental control. Depending on the types of missions and aircraft utilized, different parts of the environment need to be tightly controlled. Here are just two examples:
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Infection Control – Infection control is non-negotiable for medevac and air ambulance interiors. We utilize nonporous and antimicrobial surfaces that are resistant to chemical disinfectants. Seamless floors and monolithic cabinets are deployed to eliminate spaces prone to pathogen collection.
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Lighting Control – LED lighting arrays capable of mimicking natural light cycles can enhance both VIP and rescue mission interiors. Control lighting helps VIPs rest during flight while also ensuring maximum alertness among rescue crews operating at night.
Anything we can do to maximize interior environments for both safety and function is worth considering. This is arguably one of the most difficult aspects of designing aircraft interiors because there is so much in play.
Form and Function Through Modularity
We take great pride in having mastered the final design element: achieving both form and function through modularity. We have built our entire business on the concept of modular design capable of giving each client exactly what they need for their missions.
Modularity allows for the maximum number of layouts. It allows for different setups and equipment types that can be hot swapped on a moment's notice. Through modularity, an entire interior can be reconfigured in a short amount of time, making it possible to use the same aircraft for different types of missions.
Designing a custom aircraft interior goes way beyond mere aesthetics. A lot of science goes into giving our clients exactly what they want. The time and effort we invest are worth it, especially when an aircraft finally takes to the skies.
FAQs
Does FST testing look different for medevac and VIP interiors?
The baseline standards for both are similar and consistent. But because VIP interiors involve more natural and luxurious materials, they require more specialized chemical treatments to meet FST standards.
Is vibration fatigue a problem for medevac crews?
The constant vibrations experienced during helicopter flights can be problematic for medevac crews. We combat those vibrations with multiple strategies, like dampening materials, vibration absorbers, and ergonomic seating.
Are nonporous materials required in medevac interiors?
Yes. In order to meet strict safety standards, nonporous surfaces are a safety spec for both air ambulances and medevac interiors.
Why is modular design so important to mission-critical interiors?
Modular design is standardized by nature. It utilizes plug-and-play interfaces that facilitate rapid reconfiguration on a per mission basis.
What is 16G dynamic testing and why does it matter?
The force of gravity during an emergency landing can be upwards of 16G. Therefore, testing ensures that interior components can withstand that amount of force while keeping passengers safe.
