After they are received from the final assembly line (FAL) in France, Germany or the United States, aircraft are assembled here. Customization takes place, including avionics, interior and customer specific mission options.

Once the aircraft begins to take shape, it makes its way to our state-of-the-art down draft paint booth. The paint process starts with preparation of the airframe by sanding, masking, etc.

The customer’s preferred paint scheme and design is then applied. Following the paint application, the aircraft is ready for weighing, and after a period of drying and inspections, the helicopter is ready for takeoff.

When it is time for the aircraft to be moved to the flight line in preparation for final delivery, it is weighed and final tests are completed.

The first in a series of tests is the ground run where the helicopter engines are tested for functionality while on the ground. Once engine operations and aircraft systems pass the test, the aircraft is ready to take flight.

The Upholstery Department is responsible for installing custom seats, carpets

 and fabricated covers for the aircraft interiors. Customers are given the choice of standard STC interiors or a custom interior.

Materials used to upholster the aircraft are tested to ensure they meet fire resistance standards.

Airbus Helicopters Canada specializes in the manufacturing of composite tooling and support of all metallic tooling efforts.

Master tooling is fabricated here at the facility, manufactured from carbon fibre and glass material tools for layup of composite parts. Additionally, manufacturer’s tools for trimming and assembly are produced here.

These tools are then used to produce parts where the technician applies several layers of pre-preg.

The Composite Cutting Room contains computerized cutting tables, where composite material is cut and layup kits are prepared.

Trunest & Cutworks software is used to optimize material yield. Raw material is then stored in a 900 sq ft freezer and kept at a constant temperature of -18⁰ to -20⁰ Celsius.

This is the first step in the composite manufacturing process, where raw material will begin to shape and form to eventually create the finished component.

To ensure design specifications are met, highly advanced engineered resin systems and honeycomb core are used.

A laser system orientates ply placement and positioning, ensuring production quality.

The Composite Curing Department is responsible for curing and strengthening material through various processes.

Manufactured parts are taken to the autoclave where temperature, pressure and a vacuum process are used to transform the raw materials into lightweight and high strength composite components.

A computerized system manages the cure cycle to ensure conformity of process specifications.

After the curing process, the Composite Prep & Prime department prepares the component for further assembly, trimming and smoothing surfaces to ensure a clean and even finish.

Within the area, an engineered collection system is used to capture and extract dust.

Composite Assembly Room 2 is home to the H225/H215 program.

Calibrated bonding jigs, the thermal press and curing ovens support this activity, centralizing the assembly capabilities required for high quality parts to be produced on time and on cost.

This is the area where the final assembly of metallic parts to composite components take place, including quality checks to ensure assembly can be fitted directly to aircraft.

The Starflex repair station provides an opportunity to inspect and repair damage sustained to the Starflex while in service.

First, visual and dimensional inspections are completed to determine if the Starflex remains a candidate for repair.

Should the part qualify, the repair begins with bushing removal, followed by non-destructive testing. New bushings are then installed through a complex bonding procedure and finalized with a verification and certification process.

Our composite repair station is dedicated to reworking and strengthening minor defects that may occur due to the complexity of the part design, or tooling.

Composite Assembly Room 1 is home to the H145 program. Here, parts are assembled and quality checked before they are shipped.

After trimming, the parts move into this room. They are bonded in fixtures or initially equipped with parts and quality tested before heading to Prep and Paint. The parts then move back into the Assembly Room for final assembly, to attach other composite components, latches, etc. At this stage, parts are quality checked again. After approval, they are shipped to respective areas across the globe.

The Material Inspection Department is the home to the Faro Arm, used to scan and measure critical dimensions.

The tests performed as part of the material inspection include:

• Differential scanning calorimetry
• Peel and drum peel tests
• Interlaminar shear strength testing

QA Kitting performs a variety of inspections. Its purpose is to ensure conformity of all components in accordance with design specifications.

In this area key kitting processes are completed, including:

• Detail and assembly dimensional inspections
• Kit inspection
• Inspection of kits going to customers
• Calibration of tools

The QA – Non Destructive Testing Department supports Composite Manufacturing and Repair & Overhaul activities.

Types of Non-Destructive testing methods include:

• Ultra sonic inspection
• Magnetic particle inspection
• Liquid penetrant inspection
• Eddy current inspection

Thousands of spare parts, tools and ground support equipment are dispatched from the Fort Erie warehouse. Hundreds of customers looking for specialized parts, efficient delivery and competitive pricing rely on this warehouse and its systems to support their missions.

Using a worldwide stock management system allows ease in monitoring the materials going in and out of the plant, ensuring required inventory is always on hand.

After materials are ordered, they are quality checked and packaged to be shipped out via the shipping and receiving dock. Thousands of orders are shipped and received through this dock annually to support Airbus customers.

The Metallic Manufacturing Department consists of the machine shop and metal fabrication. This department is responsible for manufacturing metallic components and assemblies that fly on aircraft around the world.

As a specialized activity, this facility produces all metallic parts for North America, including aircraft parts, components, manufacturing kits, assemblies and options, cable cutters, cargo mirror assemblies, blade tie down kits and more.

Fabrication and assembly of metallic machined and formed parts take place in three steps; forming, bonding and assembly.

The Repair and Overhaul Department provides comprehensive repair and overhaul services for dynamic and hydraulic components, including blades and airframes.

This facility is Level I-IV certified for repair and overhaul of all dynamic components, mechanical assemblies and hydraulic systems for the H120, H125, H130, BO105 and BK117 product lines.

The Fort Erie facility is the centre of excellence for the North American region for single engine gear box repair.