DEVELOPMENT & DESIGN
Aircraft are designed at GROB by highly trained and experienced aeronautical engineers using state-of-the-art 3D CAD systems.
These contemporary digital tools enable engineers to develop and design optimized aerodynamic contours and highly durable structures within a limited timeframe.
The design process is supported by Finite Element Analyses enhanced software solutions featuring computer codes that enable detailed and precise strength and resistance analysis, while supporting the optimization of lightweight structures via stress monitoring.
Lightness and exceptional strength are primary characteristics of full composite airframes. With smooth, rivetless surfaces, these carbon fiber structures permit superior aerodynamics. With significantly less exposure to corrosion or fatigue damage than metal, composite technology translates into low maintenance costs.
Over the years GROB has established a proven track record of excellence in applied composite aircraft technology. For example, during the STRATO 2 C project the company developed and built one of the world’s largest single piece composite wings with a span of 185 ft (56.5 meters). This won the company recognition as a world leader in the field of design and production of composites.
The competitive advantages of composites include superior aerodynamics - owing to the material’s lightness and solidity - coupled with flexibility and high impact resistance. Even in case of damage to the airframe, onsite repairs are usually quick, easy and relatively cost effective, thus keeping down-times to a minimum.
Accuracy and precision are inextricably linked to the entire production process, with respect to aircraft components. The use of precision molds is one of the numerous measures taken to guarantee the quality and efficiency required.
As an integral part of the manufacturing process, a range of negative molds and jigs is used to guarantee the efficient serial production of high-quality components, from small frames or ribs to complete fuselage shells. These accurate composite counterparts ensure that matching components are joined with extreme precision. Each fuselage half is thus manufactured in its respective mold. All frames, floor panels, webs and control rods are installed in the right-hand shell before the two halves are bonded together.
Even all-composite airframes require some metal parts such as machined brackets, hinges, and supports. At GROB, comprehensive in-house metalworking facilities are involved in producing a wide array of tailor-made metal components out of stainless steel, aluminum, and titanium.
TESTING & CERTIFICATION
GROB has at its disposal a wide range of facilities and resources necessary for ground and flight testing. Stress rigs and calibration equipment are employed to carry out fatigue and strength testing required for airworthiness approval. This includes assessing damage tolerance by deliberately introducing manufacturing defects for testing purposes.
GROB has unparalleled experience in testing and internationally certifying composite airframes and components.
The GROB flight test team is an established and highly experienced group of flight testing and certification professionals. To ensure optimal results, onboard recording and telemetry equipment is used for capturing all necessary flight data.
In close cooperation with EASA / JAA and Germany´s LBA, GROB Aircraft SE has developed and established test and certification procedures to guarantee that all materials used in manufacturing aircraft comply with rigorous airworthiness criteria.
At the GROB laboratory, state-of-the-art equipment is used for careful scrutiny and routine testing of materials such as adhesives, support materials and reinforcing fibers.
EASA / JAA-approved inspectors examine and record each stage of the manufacturing process to ensure that every aircraft produced by GROB Aircraft SE meets the highest possible standards of manufacture and airworthiness.