The STC Process

7/28/2019 The STC Process

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The STC Process

Presented by:Olympic Aero Services Inc.

www.faastc.com


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Introduction

The FAA and Your Company

Does Your Company have to make a safe or an

airworthy product? Airworthiness/FARs

The path to airworthiness. The STC process.


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The FAA and Your Company

Your Company could

manufacture a variety of items.

Fortunately/Unfortunately themajority of these are installed in

aircraft.


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The FAA and Your

Company(cont) If you modify an

aircraft...the FAA must

approve every aspect: The design

Electrical, Structural

Manufacturing

Does the product matchthe design?

Others?


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Question?

Does Your Company have

to make a product that is

safe when installed orairworthy when installed?


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Answer

The answer is both.

Safe - When installed will not cause harm to

the aircraft or the operator.

Airworthy - When installed the entire

aircraft complies with the Federal Aviation

Regulations (FAR). Several portions of theFARs address safety--if airworthy, it is safe.


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Federal Aviation Regulations

(FARs) Describes how an aircraft

should be designed,

manufactured andmaintained.

Engineering=Design

Production=Manufacturing

Maintain=Customer


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Parts 23,25,27,29

Part 21 (see the PMA Manual)

Part 23 small aircraft (172, 182)

Part 25 Transport Category ( 747, GV)

Part 27 small helicopters (Astar, Bell 206)

Part 29 Transport Category (Bell 412)


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FARs (cont)

Within each part are

broad categories:

Flight loads Flammability

Electrical Equipment

Mechanical

Interiors

Flight

Loads

Flammability.

Structure

Interiors Electrical


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FARs (cont)

The FAA wants to know how you are going

to show that the aircraft is in an airworthy

(meets the FARs) condition after you install

your system.


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The STC Process

Type Certificate - Data that describes the

aircraft, the limitations, and the FAR

revision level.

STC - Supplemental Type Certificate is

essentially a change to the TC. A change

by Your Company must comply with theinformation in the TC and result in an

airworthy aircraft.


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The STC Process

Step 1: Sales sells a new

product or an old product in a

new aircraft (new to YourCompany)


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The STC Process (cont)

Step 2: Engineering creates a certification

plan (this tells the FAA Your Companys

plan of how you are going to make theaircraft airworthy after you change it).


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Step 3: Submit the certification plan to the

FAA for approval. The FAA has X number

of days to approve/change your plan.

Step 4: Engineering creates all the reports,

drawings and tests to demonstrate

compliance with each section of the FARsidentified in the certification plan.


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Examples:

25.561 (Emergency Landing Conditions)

Pull Test-Build Prototype and pull test

Comparison-This is the same as....

Analysis-Stress Engineers model and calculate.

25.609 (Protection of Structure) You might add finish instructions to drawings(anodize or powder coat)


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Examples:

25.785 (e)(f) (Seats, Berths...)

Analysis or test for a 170 lb person

By the way (Part 23 is 215 lbs)

25.853 Compartment Interiors (Flammability)

Create samples and send out for testing


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Examples:

25.1309(b)(1): Create a

failures modes andeffect analysis (FMEA)

25.1353(a): Perform an

Electro-Magnetic

Interference (EMI) test.


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Step 4: Engineering

creates reports...

Who says that thereport, drawing or test

actually demonstrates

compliance with that

particular FARsection?


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Step 5: Design data approval. The FAA is

the only person that can say yes your

test, report, comparison demonstratescompliance with that FAR section.

Remember, you have to show that Your

Companys product meets therequirements of each FAR section so the

aircraft will be Airworthy.


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Step 5 (cont): Design data approval. The

FAA can only handle about 5% of their

requests for approval of design data. So theFAA then created the designee system.

A Designated Engineering Representative

(DER) is a person designated by the FAA toact on their behalf to approve design data.

DERs have specialty areas.


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Step 5 (cont): Design data approval. A

DER uses an 8110-3 form to communicate

to the FAA that a report, drawing or testmeets the requirements of a particular FAR

section. This is not approval of the entire

installation.


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Step 5 (cont): Design data approval. A

DER cannot approve the physical

installation--thats a designatedmanufacturing inspection representative

(DMIR) see PMA manual.


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Step 6: After all the design data is

approved by a DER you submit the package

to the FAA. If they approve the data--thenthey give you permission to install a

prototype in an aircraft.


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Step 7: Conformity Inspection: After

installation, the DMIR/DAR conforms the

installation. Verifies that the installationmatches the drawings.

Step 8: Conduct any tests (EMI, Functional)

Step 9: Interior Compliance (Normally bythe FAA.) Do you block exits, head strike,

aisle width, placards?


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Step 10: Update the paperwork and then do

a final submittal to the FAA.


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The FAA issues you

an STC for a particular

model aircraft. YourCompany can now

install this STC on any

aircraft of this type!


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Other Comments

Olympic Aero Services considers the FAA as avaluable partner and we strive to continually foster our

relationship with the FAA based on trust, integrity,

and excellence.

Olympic Aero Services can provide all the help andsupport you need to get your idea STCd. Please call

us at 253.222.7086 or visit us on the web at

www.faastc.com.

Documents

The STC Process