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Elements and Performance Criteria

  1. Investigate requirements of aeronautical structural design projects
  2. Apply aeronautical structural design techniques
  3. Report results

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Aeronautical engineering refers to:

The engineering discipline concerned with the conceptual development, research, design, manufacture, implementation, installation, commissioning and maintenance of aerospace structure, mechanical, hydraulic, pneumatic, fuel and fire products, processes, systems or services for civil and military applications

Aircraft structure and structural components include:

All primary, secondary and tertiary structures that may be made from metal or fibre composite

Context of engineering design activity includes:

Competitive market

Geo political factors, such as access to materials and markets

Technological advantage/disadvantage

Resources supply: materials, labour and skills

Sustainability issues relevant to design task, including

social, economic and environmental considerations

material and energy resources

WHS, risk, and applicable standards and code requirements

Regulatory requirements and procedures associated with design, modification and repair of aircraft structure and structural components

Planning processes include:

Establishing design parameters and design criteria

Contributing to the negotiation and advice process

Preliminary planning, design investigations and costing

Identifying design, development, prototyping activities and skills requirements

Planning and scheduling design activities

Improving, adjusting, rescheduling as required by emergency contingencies and constraints

Design process includes:

Establishing design parameters and criteria

Researching, measuring, experimenting and investigating

Generating ideas

Synthesis, problem solving, decision making and addressing constraints

Applying scientific principles, calculation and graphics, prototyping and mock-up techniques

Evaluating solutions against design criteria

Consultation, adjustments and agreement

Finalising design and sign-off

Design criteria includes:

Regulatory requirements and associated standards

Function

Aesthetics

Manufacturability and maintainability

Marketability

Sustainability:

social, economic and environmental

material and energy resources

Cost constraints

Ergonomics and anthropometrics and physiology

Facilities, plant and skills available

Safety and risk

Design analysis includes:

Static and dynamic analysis of loads

The stresses and deformations resulting

Graphical and mathematical methods and software options

Design application (under professional engineer guidance) includes:

Design of structure and structural components

Design of structural modifications

Design of repair schemes

Extension of published repair schemes

Extension of corrosion removal limits

Configuration management (CM)

CM is a process for control and documentation of the design and development process and for the management of system, component and software throughout the service life

Integrated logistic support (ILS)

ILS is an integrated approach to the management of logistic disciplines originally developed for the management of military systems from design concept to final disposal at life-of-type. It covers:

reliability engineering, maintainability engineering and maintenance planning

supply and support

support and test equipment

manpower and personnel

training and training support

technical data and publications

computer resources support

facilities

packaging, handling, storage and transportation

design interface

Sustainability considerations include:

Resources and energy required for design

Life-cycle design of product (manufacture to remanufacture or recycle)

Environmental considerations in manufacturing and operation of design, including:

raw material, solids and hazardous waste, and production by-products

potential contamination of land, air and stormwater pollutants, and discharge to sewerage

Carbon pollution and reduction effects

Prototyping includes:

Any combination of:

mock-ups

physical and virtual modelling with post-processing for comptuer-numerically controlled (CNC) and rapid prototyping

Systems thinking includes:

The process of developing solutions within the context of an entire system

Recognising that an improvement in one subsystem can adversely affect another subsystem

Appropriate technical and professional assistance includes:

Assistance from individuals with CASA maintenance certification licences or those with supervisory authorisations in the ADF regulatory system

Professional support from engineers employed within:

organisations with CASA design, continuing airworthiness management or maintenance approvals

approved engineering organisations under the ADF regulatory system

Engineers employed within organisations recognised by overseas airworthiness organisations

WHS, regulatory requirements and enterprise procedures include:

WHS Acts and regulations

Relevant standards

Industry codes of practice

Risk assessments

Registration requirements

Safe work practices

State and territory regulatory requirements applying to electrical work

Civil Aviation Safety Regulations (CASRs)

AAP7001 .053 ADF Technical Airworthiness Management Manual

Overseas airworthiness authorities, where applicable, e.g. Federal Aviation Administration, Transport Canada, European Aviation Safety Agency

Relevant standards include:

AS 1100.101-1992 Technical drawing – General principles

AS 4024.1-2006 Series Safety of machinery

AS/NZS ISO 31000 Set:2013 Risk Management Set

British Defence Standard 00-970 Design and Airworthiness Requirements for Service Aircraft

US Military Specifications and Standards relevant to aircraft design

ADF AAP7001 .054 Airworthiness Design Requirements Manual

FAR Part 23 Airworthiness Standards for Airplanes in the Normal, Utility, Aerobatic or Commuter Categories

FAR Part 25 Airworthiness Standards for Airplanes in the Transport Category

EASA CS-23 Certification Specifications for Aeroplanes in the Normal, Utility, Aerobatic or Commuter Categories

EASA CS-25 Certification Specifications for Airplanes in the Transport Category

CASA AC 21-99 Aircraft Wiring and Bonding

FAA AC 43-13-1B Acceptable Methods, Techniques and Practices – Aircraft Inspection and Repair

AC21-15(1) Supplemental Type Certificates

AC21.16(0) Approval of Materials, Parts, Proceses and Appliances

AC21.14 Production Certificates

AC21.20 Production Under a Type Certificate Only

AC21.27 Manufacturing Approval – Overview

AC21.145(0) Manufacture of Parts During the Course of Maintenance

AC21-601(0) Australian Technical Standard Order

CAAP35 -7(0) Design Approval of Modifications and Repairs


Performance Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

communicating, negotiating and reviewing context and parameters of the engineering design brief with stakeholders

determining or confirming scientific principles and design techniques, WHS and regulatory requirements, and design specification requirements

evaluating multiple solutions against design criteria, risk, sustainability and cost

investigating life-cycle design and sustainability, technical and professional assistance required

investigating and applying CM and ILS requirements

planning, scheduling and coordinating the design task

applying design process and scientific principles to structure and structural component design proposals, including modifications and repairs to existing structure

solving problems and making decisions with systems thinking for contingencies and constraints, including airworthiness regulatory requirements and continuous improvement (may be requirements of CM and ILS)

defining designs, specifying, documenting and applying graphical techniques, modelling, mock-up or prototyping techniques

creating and maintaining adequate and accurate calculations and design process records

reporting and documenting results of investigations, application of principles and techniques, calculations, specifications, diagrams, computer-aided design (CAD) files, mock-ups or prototypes of designs

complying with regulatory procedures for design, modification and repair approval.


Knowledge Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

life-cycle design and sustainability implications of aircraft structure designs (may be part of CM and ILS procedures)

design processes and techniques to investigate, synthesise and develop proposals, evaluate feasibility against design criteria, review and revise in consultation with stakeholders, model, mock-up and prototype

systems thinking, problem solving and decision making, and continuous improvement methods

application of CM and ILS procedures

WHS and regulatory requirements, codes of practice, standards, risk management and registration requirements

The roles and relevance to the design process of professional and technical assistance for engineering specialisations

procedures for planning, scheduling and coordination of design

hardware requirements of typical aircraft structure and structural components

engineering scientific principles required for design analysis

design calculations techniques

application of software for product planning and design, such as CAD, stress analysis and mould design and project management

required documentation, including:

design brief and records of negotiation

planning and schedule

calculations and diagrams documentation for checking and design records

specifications and graphics required to define designs

risk analysis report

design process summary report

life cycle and sustainability reports

CM and ILS documentation

documentation required by Regulators for approval of designs, modifications and repairs

prototyping options, including mock-ups, physical and virtual modelling, and rapid prototyping.