Airframe Designs - Company Brochure

We help customers to solve complex engineering problems, providing expertise in engineering design, analysis, certification and advanced manufacturing. Excellence in engineering

Excellence in engineering

We help customers to solve complex engineering problems, providing expertise in engineering design, analysis, certification and advanced manufacturing.


Airframe Designs has been in business for over a decade, providing specialist engineering services to a wide range of customers primarily in the aviation, defence, and space sectors. We are comprised of a team made up of highly experienced engineers (design, analysis, certification, and manufacturing) capable of delivering optimal solutions for mechanical structures in a digital environment. In the primary sectors, we provide engineering solutions for new design, modifications, repairs and reverse engineering for major airlines, special mission platform operators, military fleets, and VIP customers covering both Aircraft and Rotorcraft platforms. We have widespread experience in the civil sector with regular exposure to cabin interior upgrades, VIP configurations, and system upgrades that impact on airframe structure. Airframe Designs regularly engage with customers requiring design and certification support to special mission products and role fits such as: Aero-Medical; Police; Flying Schools; Search and Rescue; Transportation of Cargo; Oil Spill Response; and Crop Spray. We work closely with several OEMs and Prime Contractors to support various fleets of military aircraft and helicopters including platforms designed to simulate Electronic Warfare Threats. We also offer a turn-key solution for product delivery by providing design, analysis, certification, and manufacturing to enable delivery of mechanical components and assemblies, all aspects of tooling, and 3D printed polymer parts. In addition to the aviation, defence and space sectors, we also operate in the nuclear, marine, medical, automotive and rail sectors.

OUR PURPOSE To bring skills, experience and innovation to the aerospace supply chain in design, analysis, and manufacturing by nurturing and developing engineering talent. OUR VISION To challenge and transform traditional engineering and manufacturing by embracing change, technology and innovation and by setting new benchmarks.


CUSTOMER-CENTRIC From beginning to end

Professor Andrew Schofield Chair of the North West Aerospace Alliance Their highly experienced team demonstrates a really positive culture as they are extremely innovative and collaborative in their approach. It is a pleasure to work with them. AFD are a key member of the North West Aerospace Alliance and play an active role across the community.

INTEGRITY In all that we do

INNOVATION To remain in front

ONE TEAM Making us stronger together



Excellence in engineering

How we help customers

Challenges Solving complex engineering problems Controlling cost and schedule Building effective and efficient teams Relieving bottlenecks Reducing carbon footprint

Remedies Experience, knowledge, expertise, collaboration Fixing cost, sharing risk, on-time delivery Integrating, optimising, continually improving Availability, agility, reliability Solar, Battery Storage, ESG Policy



Excellence in engineering

Our Capabilities

Our capabilities encompass:



Certification Manufacturing

Our design capability stretches across mechanical structure, tooling, and test rigs, bringing extensive experience in CAD modelling from concept to first article inspection. Design

We have three teams within the business covering Stress, Design, and Additive Manufacturing. We have contributed to over 500 projects in collaboration with a wide array of customers, with our team bringing knowledge and experience spanning five decades. We have experts appointed by customers to check and verify engineering data.

We deliver accurate and reliable 3D models and 2D datasets to enable the manufacture of mechanical products. Our team is highly familiar with the gated design review process and design steps from concept through preliminary, critical, and final design review (PDR, CDR and FDR). Our baseline tool-set includes CATIA. However, our team is also well-versed in several other CAD systems including Siemens NX, Solidworks, Inventor, and CREO. We also provide support in reverse engineering, designing for additive manufacture (DfAM), and legacy data digitisation, utilising VERISURF software for converting scanned data-point clouds into usable CAD models and surfaces.

AFD was engaged from start to finish in our Taipan Gun Mount programme, providing reliable specialist support in the structures topic. During both the prototype and serial production phases, AFD supported both GVH UK and GVH AU in solving complex strength issues, preparing the ground for a successful certification campaign. AFD offer a turn- key Structures solution for EASA DOAs by providing a team of experienced Stress Engineers backed up by independent Compliance Verification Engineers (CVEs).

Gareth Dyer Managing Director – International, at NOVA Systems



Excellence in engineering

Our core capabilities cover traditional static stress analysis (hand calculation), FEM (Finite Element Modelling), and F&DT (Fatigue and Damage Tolerance) evaluation. Analysis

Our team is highly familiar with current IATA, CAA, FAA, EASA, and UK MAA regulatory requirements, alongside historical JAA, CAR, and BCAR equivalent airworthiness specifications. Certification

We assist UK-CAA & EASA design organisations in the certification of changes or repairs to aircraft and rotorcraft providing a peer review service of elected certification basis, certification plans, and compliance demonstration evidence.

Our CVEs (Compliance Verification Engineers) visit test facilities to witness and verify test activities that underpin certification, and we hold regular dialogue with the competent authorities. As a turn-key package of support we can independently compile and verify substantiation evidence, working within the framework and constraints of the customer design organisation policies.

We also provide support in the assessment of vibration, bird strike, and aerodynamics, including CFD (Computational Fluid Dynamics). For traditional static stress analysis, we use a combination of hand-calculations, MATHCAD computation, Excel Spreadsheets, and PYTHON scripting to check the strength of metallic, non- metallic, and composite structures. We perform analysis to suit the client needs, whether this be initial sizing to support conceptual design phases, or final design calculations to support project certification submissions. Our primary finite element modelling tool is MSC ONE, using NASTRAN code with PATRAN and APEX pre and post processors. This provides an advanced meshing and generative design capability that streamlines CAD clean-up and simplifies the meshing and modelling workflow.

Our engineers are highly familiar with the techniques employed for modelling airframe thin- walled structures using beam and shell elements (e.g., major fittings) using 3D TET or HEX solid elements. We perform Fatigue Analyses using either a stress- based (s-N) or strain-based (e-N) approach and develop the necessary analysis tools from first principles to suit the analysis requirements and needs of the customer. For Damage Tolerance we conduct a crack growth assessment using in-house scripts, client-supplied software, or commercially available tools such as AFGROW or NASGRO. We have extensive knowledge in the F&DT assessment of fuselage penetrations for antenna feed-throughs and the substantiation of modified Fatigue Critical Structure.

We awarded the monument stress analysis to AFD owing to their extensive experience and knowledge in analysing this kind of structure and their pro- active approach to resolving technical difficulties often encountered in the design phase. The added value of using AFD was their pre-existing relationship with our customer (the DOA) enabling AFD to compile, check and verify the structural substantiation.

Kevin Hann, Engineering Manager, JETMS Completions



Excellence in engineering

Our focus is additive layer manufacturing of polymer parts, prototypes, trial-fit mock- ups, and lightweight tooling. Manufacturing

AFD is a team of highly experienced engineers (in design, analysis, certification and manufacturing) capable of delivering optimal solutions for mechanical structures in a digital environment. Our Team

A dynamic, highly driven, and customer focussed company owner, CEO, and Chief Engineer. Jerrod began his career at British Aerospace (now BAE Systems) as an Apprentice Fitter before progressing into the Stress Office at Warton, Lancashire. After 13 years at BAE Systems, Jerrod branched out to work abroad for Boeing in the USA, for Fokker in The Netherlands, and finally for Airbus in Germany. In 2009, Jerrod returned to the UK to establish Airframe Designs and set about meeting the increasing demand for specialist stress analysis services to EASA Part21 Design Organisations across the UK and Europe. An experienced design engineer with a thorough understanding of airframe and mechanical structures. Chris began his career at British Aerospace (now BAE Systems) as an Apprentice Fitter before progressing into the Design Office and later the Design Liaison Department at Warton, Lancashire. In recent years, Chris has specialised in the delivery of test-rig structures, mould and trim tooling, jigs and fixtures, lifting and handling equipment, and ground support equipment. After eight years with BAE Systems, Chris ventured overseas and continued to gain over 30 years’ of valuable experience across a wide range of OEM and Tier 1 suppliers including the likes of Boeing, Airbus, Terma, Marand and Assystem.

Jerrod has over 30 years of experience in the Aviation Sector and is an accomplished Structural Compliance Verification Engineer (CVE) for a wide number of customers. He is firmly focused on maintaining high standards within the business to meet customer expectations and to ensure delivery of engineering services that fit with the high standards laid down by the sectors in which AFD operate. This sits alongside an ambition to grow the company and set the benchmark for the supply of such services to the aerospace, defence, and space industries. Jerrod was also recently appointed a Fellow with the Royal Aeronautical Society, a testament to his hard work and dedication within the aerospace industry. In 2008, Chris returned to the UK to head up the Design Office for a leading North-West aerospace manufacturer, supporting the delivery of turn-key packages for major industrial players in the aviation, defence and space sectors. This role involved working closely with the manufacturing supply chain and forging a very practical appreciation of design, engineering and manufacturing. As Design Manager at AFD, Chris brings a leadership mentality alongside his wealth of experience and keen enthusiasm for engineering problem-solving. Chris is well versed in bringing design packages to fruition and seeing them through to manufacture under tight timescales, and will be instrumental in developing and focusing our design capability to support existing and future work packages.


Our advanced manufacturing facility houses an array of FDM printers and ancillary equipment including a Stratasys Fortus 450mc for the production of ultra- polymer materials such as ULTEM 9085. We utilise a hand-held laser scanner for inspection (part geometry validation), reverse engineering, and airframe surveys.

We are actively involved in R&D and the demonstration of innovative technology through partnerships with industry specialists in advanced manufacturing, universities and research centres. These technologies can significantly reduce manufacturing lead-times, improve quality, benefit the environment, and ultimately reduce life-cycle costs.


We engaged AFD on the Human External Cargo programme at a critical point when EASA had just begun to scrutinise our first STC application for the Load Carrying System / Basket Type 1. At this time AHUK faced a number of technical challenges and simply put, AFD offered quick and effective support; working as a team with us to resolve some challenging technical problems, enabling confidence to be built between AHUK and EASA at panel level, and ultimately leading to a successful STC application.

Jim Townson, Head of Design, AIRBUS Helicopters UK



Excellence in engineering

Our Team

Who we work with

AFD operates at every level in the aerospace, space and defence supply chain, working with the smallest of EASA Approved Part21J Design Organisations all the way up to some of the largest global Original Equipment Manufacturers (OEMs) and prime contractors.

A very experienced principal stress engineer with an aptitude for leadership and team management. Lisa began her career at British Aerospace (now BAE Systems) as an Apprentice Fitter before progressing into the Stress Office at Warton, Lancashire. After 8 years at BAE Systems, Lisa spent some time as a Senior Lecturer in Engineering at Blackpool & the Fylde College before returning to industry.

Lisa has worked for Bombardier in Canada, Jet Aviation in Switzerland, and SAAB in Sweden, but decided to return home to Blackpool in 2019 and join Airframe Designs in a leadership role. She has 18 years’ of experience in the Aviation Sector and is appointed as a Structural Compliance Verification Engineer (CVE) for several UK and European customers. As the Structures Lead Engineer, Lisa leads the entire team of Stress Engineers to ensure that benchmark processes are being followed and on-time delivery is accomplished, to the right quality, and within budget.

We understand the prerequisites for obtaining Approved Supplier Status in these highly regulated sectors and strive to meet the highest standards and expectations in terms of our Integrated Management System (IMS), IT systems and toolset, staff development and training, insurances, and security measures.


An experienced manufacturing engineer with a significant practical background in engineering. Most recently, Garry gained a first class degree in Automotive Performance Engineering at the University of Bolton, followed by a period of employment by the university in supporting the development of a new additive manufacturing research centre. With over 18 years’ of manufacturing experience in the injection moulding sector, Garry is a highly skilled analytical engineer with an aptitude for developing and implementing solutions to manufacturing issues.

Garry is familiar with a wide array of additive manufacturing technologies for both polymer and metallic materials and is skilled in using Fused Deposition Modelling (FDM), Laser Powder Bed Fusion (LPBF), and Stereolithography (SLA) systems. At AFD, the remit for Garry is to lead the development and growth of the manufacturing team and production facility, working closely with our design, stress and certification specialists to enable the delivery of optimum products to a diverse customer base.


AFD provided valuable support to a complex and challenging upgrade involving our customer, production and maintenance organisations, our US design office, and the responsible Military Aviation Authority. AFD always responded positively and effectively to support requests and their involvement in critical design reviews became essential in closing down queries and clarifying engineering decisions.

Johannes Hien, Head of Design, Tenencia Aerospace



Excellence in engineering

Environmental Commitment

We are committed to cutting emissions by 50% by 2030 and achieving net-zero emissions by 2050. Our dedication to a sustainable future drives us to implement innovative technologies and adopt sustainable practices to reduce our carbon footprint.

22.5kWh Battery Storage

80 Solar Panels

Certified to ISO 14001

Race to Net Zero 2050




For more information

01253 400320

Airframe Designs 11 The Pavilions Avroe Crescent Blackpool FY4 2DP 01253 400320

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