Eagle Aviation

3200 Magruder Blvd

Hampton Virginia 23666

Tel 757.224.6269

Fax 888-577-1193

www.eagleaviationtech.com

ISO 9001:2000

(w/design) & AS9100 Rev B

Experience the Spirit of Experience the Spirit of Experience the Spirit of

Eagle Aviation!Eagle Aviation!Eagle Aviation!

Eagle Aviation is at the heart of modern aviation space travel, marine industry, and others. The principal areas of operation include prototype components, systems development and production. Whatever your program requirements are -- Eagle Aviation is ready and excited to meet the challenge!

Give us the opportunity to earn your business !

Small Woman Owned Business

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Brand New 2008 Autoclave Usable Size: 5’X21’ (Nominal inside working area) Psig / Temp. Rating: 150 psig / 625°F

Two Clean Room Complex Air Cleanliness: FED STD 209, ISO 14644, SS9309 4,000 sq ft qualified space 2008 Gerber DCS 2500 Ply Cutter Temperature control: 65 deg F to 80 deg F Humidity: <= 60% relative humidity Particle count: <2,000 particles/ft3 larger than 5 micron Positive air pressure AS9100 Design, prototype development and production operations have a certification to the ISO 9001:2000 (w/design) & AS9100 Revision B, International Quality System Standard

S E R V I C E S A V A I L A B L E

What’s New: ENGINEERING– DESIGN, ANALYSIS & TESTING

Systems integration and testing

Extensive experience in rotor blade development, static and fatigue testing of advanced composite structures

SolidWorks, CATIA V5, Pro-E, KeyCreator ANSYS, Nastran, ALGOR, COSMOS

Instrumentation COMPOSITE SHOP

Fiberglass, graphite, Kevlar, wet layup and pre-preg Tooling design and development

Curing techniques include autoclave/ovens PRECISION MACHINE SHOP

3, 4, 5-axis machining /Mastercam programming

Experienced in complex contoured tooling

Variety of materials– aluminum, steel, titanium, invar, foam, other metals, G-10, and more

3200 Magruder Blvd Hampton Virginia 23666 Tel 757.224.6269 Fax 757.224.8912 www.eagleaviationtech.com

ISO 9001:2000 (w/design) & AS9100 Revision B

Sikorsky S-76D(TM) Helicopter Inlet Door and Engine Air System

KARI Tilt rotor Smart Unmanned Aerial Vehicle

Eagle Aviation SoarsEagle Aviation SoarsEagle Aviation Soars Above the CompetitionAbove the CompetitionAbove the Competition

X2 Technology (TM) Demonstrator

Two Clean Room Complex’s Brand New 2008 Autoclave AS9100

Sikorsky helicopter images © 2008 Sikorsky

SERV I C ES AVA I LABLE

3200 Magruder Blvd Hampton Virginia 23666 Tel 757.224.6269 Fax 888-577-1193 www.eagleaviationtech.com


Eagle AviationEagle AviationEagle Aviation---Excelling in Excelling in Excelling in Composites FabricationComposites FabricationComposites Fabrication

ENGINEERING–

DESIGN, ANALYSIS & TESTING • Systems integration and testing • Extensive experience in rotor

blade development, static and fatigue testing of advanced composite struc-tures • SolidWorks,CATIA V5,Pro-E, Key-

Creator ANSYS, Nastran, ALGOR, COSMOS • Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet

layup and pre-preg • Tooling design and development • Curing techniques incl. autoclave/

ovens

PRECISION MACHINE SHOP • 3, 4, 5-axis machining /Mastercam • Wire EDM • Complex contoured tooling • Variety of materials– aluminum, steel, titanium, invar, foam, other

metals, G-10 and more

Sikorsky X2 TM Technology

Demonstrator– Composite Rotor Blades Composites Support to

�AVSEA

Production of UAV

Composite Components

Sikorsky helicopter images © 2008 Sikorsky

Sikorsky S-76D Inlet Door and Engine Air System

Engineering, and Fabrication Prototype through Production

Eagle Aviation’s composites fabrication resources include

freezers for composite material storage, walk-in curing ov-

ens, Gerber ply cutting table, two clean rooms and an 5’x

20’ autoclave.

We have highly experienced technicians who work with

fiberglass, graphite and Kevlar materials, both cloth and

pre-impregnated, to fabricate custom complex, composite

structures. Tooling approaches range from templates to

C�C-machined forms, mandrels, and molds made from

wood, high-density foam, fiberglass, aluminum, steel, or

graphite.

S E R V I C E S A VA I L A B L E


ISO 9001:2000 (w/design)

& AS9100 Revision B

Sik X2 Technology (TM) Demonstrator

Tilt-Rotor SUAV Prop-Rotor

Design and Manufacture

5ASA PSP Rotor Blades

Eagle AviationEagle AviationEagle Aviation––– Rotor Blade Rotor Blade Rotor Blade

Design, Manufacture and TestDesign, Manufacture and TestDesign, Manufacture and Test

Instrumented Blade

Voltage Testing V-22 Instrumented

Segmented Blade

Summary of Recent Experience:

• Isolated Rotor Test System (IRTS) CAD Modeling and Re-Design

• Performed flight loads development, design, and manufacture of

flight hardware rotor blade sets for both the upper and lower rotors of

X2 Technology ™ Demonstrator manned aircraft.

• Manufacture of S-61 Main Rotor Blade qualification test specimens

for Carson Helicopters under contract to Sikorsky Aircraft Corpora-

tion, for the presidential VH3 Helicopters

• Active Twist Rotor (ATR) Blade engineering & manufacturing ser-

vices for Army Research laboratory (ARL), NASA LaRC

• FAA Certificated Carson S-61 Advanced Composite Main and Tail

Rotor Blade Development

Facilities: • Brand New 2008 Autoclave -Usable Size: 5’X21’ (Nominal inside

working area) Psig / Temp. Rating: 150 psig / 625°F

• Two Clean Room Complexes -Air Cleanliness: FED STD 209, ISO

14644, SS9309 4,000 sq ft qualified space 2008 Gerber DCS

2500 Ply Cutter Temperature control: 65 deg F to 80 deg F

• Engineer Lab—Pull Test, Fatigue Test, Risk Reduction Testing, etc

E5GI5EERI5G– DESIG5, A5ALYSIS

&TESTI5G • Systems integration and testing

• Extensive experience in rotor blade de-

velopment, static and fatigue testing of

advanced composite structures

• SolidWorks, CATIA V5, Pro-E, Key-

Creator ANSYS, Nastran, ALGOR,

COSMOS

• Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet layup

and pre-preg

• Tooling design and development

• Curing techniques include autoclave/

ovens

PRECISIO5 MACHI5E SHOP • 3, 4, 5-axis machining /Mastercam pro-

gramming

• Wire EDM

• Experienced in complex contoured

tooling

• Variety of materials– aluminum, steel,

titanium, invar, foam, other metals, G-

10, and more

© Sikorsky Aircraft Corporation 2009




E�GI�EERI�G–

DESIG�, A�ALYSIS &TESTI�G • Systems integration and testing

• Extensive experience in rotor blade

development, static and fatigue testing of

advanced structures

• SolidWorks, CATIA V5, Pro-E,

KeyCreator , ANSYS, Nastran, ALGOR,

COSMOS

• Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet layup

and pre-preg

• Tooling design and development

• Curing techniques include autoclave/ovens

PRECISIO� MACHI�E SHOP • 3, 4, 5-axis machining /Mastercam

programming

• Wire EDM

• Experienced in complex contoured tooling

• Variety of materials– aluminum, steel,

titanium, invar, foam, other metals, G-10,

and more

Custom Oil and

Lube System

Engineering Software Tools

Computer Aided Design / High End CAD Solid Modeling

CATIA V5 with CPD and CPM Modules

Pro-Engineer (Pro-E)

Solid Works

KeyCreator

Engineering structural and dynamic analysis

ANSYS, NASTRAN, Algor, and COSMOS Express

Multiple proprietary in-house spreadsheet programs have

been developed for special design tasks

600 HP Gear Box Design, Analysis, Manufacture and Test

Custom Gear and Drive Line Analysis- Using A�SYS

�ASTRA�, ALGOR A�D COSMOS

Eagle Aviation Providing Eagle Aviation Providing Eagle Aviation Providing Design and Manufacturing Services Design and Manufacturing Services Design and Manufacturing Services for Complex Mechanical Systemsfor Complex Mechanical Systemsfor Complex Mechanical Systems

Examples of Experience:

• Custom Spiral Bevel Gears

• Gear driven main and scavenge oil pump systems

• Close Tolerance hollow titanium shafting

• Ultra light weight CNC machined aluminum housings



Eagle Aviation Leading Innovation fromEagle Aviation Leading Innovation fromEagle Aviation Leading Innovation from

Research Models to Systems Development Research Models to Systems Development Research Models to Systems Development

ENGINEERING–

DESIGN, ANALYSIS & TESTING • Systems integration and testing • Extensive experience in rotor blade development, static and fatigue testing of advanced composite structures • SolidWorks,CATIA V5,Pro-E, Key Creator ANSYS, Nastran, ALGOR, COSMOS • Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet layup and pre-preg • Tooling design and development • Curing techniques incl. autoclave/ ovens




Boeing X-51 Full-Scale Antenna Performance Model – EATI performed all de-

sign and manufacturing of a full-scale composite model of Boeing’s X-51 Scram-

jet Wave rider. The model was representative of the actual aircraft’s mold lines

within 0.005 inches overall and was coated with a special conductive coating to

enhance antenna performance test operations

Develop the Aircraft Antenna Interface Adapter (AAIA) for C-130 Combat

Talon II operations. The Aircraft Antenna Interface Adapter was developed as a

near field coupler that conforms to the exterior surface of the aircraft Radome.

Near field probes are designed to accurately measure the RF performance char-

acteristics of selected aircraft antennas

Complete design and manufacture of a ground based “Iron Bird” test facility

for rotor & drive system testing, and whirl testing of the KARI Tilt-Rotor

SUAV Proprotor Blades. This system is powered by a 600 hp PW-206C turbo-

shaft engine. Completed full test site development and operations including

automated control system with real time graphical user display

Boeing X-51 Full-Scale

Antenna Performance Model

Aircraft Antenna Interface

Adapter (AAIA)

Wind Tunnel Research Model

NASA ARES-I

KARI Tilt-Rotor SmartUAV (SUAV) – EATI successfully designed analyzed,

produced tooling, manufactured, inspected, and successfully completed powered

testing of the complete rotor and drive systems for this Smart UAV system.

Efforts included design, manufacture, and fatigue test programs for the SUAV’s

advanced composite proprotor blades

ISO

9001:2000 (w/design)

& AS9100 Revision B

Mock-up for the Sikorsky X2

TechnologyTM

Light Tactical Helicopter (LTH),

a developmental coaxial rotor

aircraft capable of 250kts

Designed and built in less than 4 months

Provided all Logistics Support

Design, Tooling, Fabrication and

Assembly of components

Integration of Customer Furnished Materials

On Budget and On Time!


ENGINEERING–

DESIGN, ANALYSIS & TESTING

• Systems integration and testing • Extensive experience in rotor blade development, static and fatigue testing of advanced composite structures • SolidWorks,CATIA V5,Pro-E, KeyCreator ANSYS, Nastran, ALGOR, COSMOS • Instrumentation

COMPOSITE SHOP

• Fiberglass, graphite, Kevlar, wet layup and pre-preg • Tooling design and development • Curing techniques incl. autoclave/ovens

PRECISION MACHINE SHOP

• 3, 4, 5-axis machining /Mastercam • Wire EDM • Complex contoured tooling • Variety of materials– aluminum, steel, titanium, invar, foam, other metals, G-10 and more 3200 Magruder Blvd

Hampton Virginia 23666 Tel 757.224.6269 Fax 888.577.1193

Eagle Aviation Eagle Aviation Eagle Aviation --- Moving our Customers’ Products to the Front LineMoving our Customers’ Products to the Front LineMoving our Customers’ Products to the Front Line

Photographs © Sikorsky Aircraft Corporation 2009

S E R V I C E S AVA I L A B L E



Sikorsky S-76D(TM) Helicopter Inlet Door and Engine Air System KARI Tilt rotor

Smart Unmanned Aerial

Eagle Aviation TransitioningEagle Aviation TransitioningEagle Aviation Transitioning Manned to Unmanned Manned to Unmanned Manned to Unmanned

Agile Eagle UAV Alpha Eagle UAV

ENGINEERING– DESIGN, ANALYSIS &

TESTING • Systems integration and testing • Extensive experience in rotor blade

development, static and fatigue test-ing of advanced composite structures

• SolidWorks, CATIA V5, Pro-E, Key-Creator ANSYS, Nastran, ALGOR, COSMOS

• Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet la-

yup and pre-preg • Tooling design and development • Curing techniques include auto-

clave/ovens

PRECISION MACHINE SHOP

• 3, 4, 5-axis machining /Mastercam programming • Wire EDM • Experienced in complex contoured

tooling Variety of materials– aluminum, steel, titanium, invar, foam, other metals, G-10, and more

Agile Eagle UAV-This prototype vehicle was produced to a meet a US

Army requirement. Mission capability includes FLIR with Target

Designator, two hellfire missiles and 3+ hours of flight. Advantages

include: small footprint, ample lift and the ability to change the mission

equipment package to meet mission requirements. Can be moved into

and out of a trailer by two people. Has a universal mount currently in-

stalled for ease of attaching and detaching notional pods.

Alpha Eagle UAV- Designed and fabricated for easy maneuverability

and in field repair. Alpha Eagle can be fit into the back of a HUMVEE

by one person. Potential Tactical use can be long range 100-150 mile

radius logistical vehicle, intelligence gathering and video surveillance.

Advantages to include: 70lb payload, 5 hours of flight or can be traded

to 2.5 hours of flight for 125lb payload.

KARI Tilt-Rotor SmartUAV (SUAV) – EATI successfully designed,

analyzed, manufactured, inspected, and completed static & fatigue test

programs for the SUAV’s advanced composite proprotor blades. The

blades utilize a solid Gr/Ep laminated spar along with advanced core

construction, and fiberglass skins. In addition to the Proprotor develop-

ment for the KARI Smart UAV, EATI also performed clean sheet de-

sign, manufacture, and powered testing of the complete rotor and drive

systems for the 600-hp Tilt-Rotor system. Efforts included design and

manufacture of the powered Iron Bird test bed, including a Labview

based control system to drive and control all test parameters.

S E R V I C E S A V A I L A B L E

ENGINEERING–

DESIGN, ANALYSIS & TESTING • Systems integration and testing • Extensive experience in rotor blade development, static and fatigue testing of advanced composite structures • SolidWorks,CATIA V5,Pro-E, Key Creator ANSYS, Nastran, ALGOR, COSMOS • Instrumentation

COMPOSITE SHOP • Fiberglass, graphite, Kevlar, wet layup and pre-preg • Tooling design and development • Curing techniques incl. autoclave/ ovens



Eagle AviationEagle AviationEagle Aviation Building Quality into Building Quality into Building Quality into Every Step of the ProcessEvery Step of the ProcessEvery Step of the Process

EATI is ISO 9000: AS9100 certified. The quality manual defines the policies and procedures used to achieve the highest levels of quality and inspection documentation for engineering, fabricated hardware, including: materials purchased, customer received ma-terials, receiving, controlled storage, certification and tractability, configuration control, fabrication inspection, non-conforming hard-ware control, corrective and preventive action, metrology control, handling, packing, shipping, training, and documentation. EATI works to impart a culture where quality is considered in every step from contract award to delivery. All employees are trained to be responsible for quality assurance. We strive to instill the ownership that promotes this attitude. This helps to create an environment where quality is “built in” to our products Eagle Aviation utilizes the following quality assurance techniques within each program:

• Manufacturing Process Control

• Material Traceability

• Engineering Quality Assurance

• Contracting Quality Assurance

• Purchasing and Planning Quality Assurance

• Risk Management

• Process, Configuration and change Control

• Performance Metrics

Romer Portable CMM 3-Axis Gantry CMM

Two Clean Room Complex’s Conformance with

FED-STD-209 and SS9309

Brand New 2008 Autoclave

(5ft x 20ft inside dimensions)


Documents

Eagle Aviation