Designing and Building a Bespoke Solution for an Aerospace Client using Environmental Chamber Testing
16 October | Castlet
Sector: Aerospace
We designed and built a bespoke solution for an aerospace customer using Environmental Chamber testing.
THE PROBLEM
At Castlet, our history of research and development in a wide range of sectors – from aerospace and defence to industrial – enables us to bring together specialist design, test and build capabilities to create bespoke solutions for our customers.
Our client in the aerospace sector approached us with a brief outline of a challenge they were experiencing with no specific details – a common occurrence when working with sensitive data.
Our first consideration was whether we could safely meet the strict power, space, and weight restrictions involved in the project. To assess feasibility, we built and tested initial elements before moving forward with the full design.
This project really showcased how adaptable our team can be. Starting with minimal information, we were able to design, prototype, and test a complex system that performs reliably under harsh conditions. The key was balancing innovation with safety – making sure every design decision worked for the end user.
Brian Jones, Chief Engineer
Our Solution
Designing a solution
Drawing on our experience in testing equipment for aerospace, defence and military, we began by creating a 3D model incorporating the core elements that met the client’s initial requirements. After meeting with the client to refine key aspects, we developed a pre-prototype evaluation system.
Once we were satisfied with the preliminary results, we presented them to the client, who provided valuable feedback. Their requests for changes were integrated into the updated design, leading to the creation of a working prototype that met the bespoke space and performance requirements.
Testing the prototype
The prototype underwent rigorous testing to ensure it met the criteria outlined in the original specification. Using our Thermotron Environmental Chamber – one of just ten with an attached shaker in the UK – we simulated harsh environmental conditions and monitored system performance via sensors ported outside the chamber.
The key challenges were ensuring reliable operation under demanding conditions, maintaining simplicity for the user, and guaranteeing safety. The system was designed to be self-monitoring, to provide feedback to the user, and to operate safely throughout..
Design and development considerations
The prototype underwent rigorous testing to ensure it met the criteria outlined in the original specification. Using our Thermotron Environmental Chamber – one of just ten with an attached shaker in the UK – we simulated harsh environmental conditions and monitored system performance via sensors ported outside the chamber.
The key challenges were ensuring reliable operation under demanding conditions, maintaining simplicity for the user, and guaranteeing safety. The system was designed to be self-monitoring, to provide feedback to the user, and to operate safely throughout.
The Outcome
Following successful testing, we delivered a fully functional, tailored solution that met the client’s operational, environmental, and safety requirements. The project demonstrated our ability to take an outline concept with limited initial data and transform it into a complete, field-ready system – designed, built, and tested to aerospace standards. Find out more about our specialist design, test and build capabilities for aerospace here.
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