INFINITE POSSIBILITIES.
AERONAUTIC + AEROSPACE
PRODUCT DEVELOPMENT CONSULTANCY
PURPOSE-DESIGNED EQUIPMENT FOR ROTORCRAFT & EXTERNAL LOAD OPERATIONS.
Lightyear Aero partners with aviation manufacturers, utility rotorcraft operators, and STC applicants to lead the industrial design, mechanical layout, manufacturing documentation, and certification coordination of specialized airborne equipment.
HEC & NHEC HARD GOODS DESIGN
Clean-sheet mechanical design and mechanism layout for Human External Cargo (HEC) and Non-Human External Cargo (NHEC) equipment—focused on ergonomic handling, deterministic release geometry, and field maintainability.
- Cargo hooks, keeperless latches, & belly suspension assemblies
- Primary & Backup Quick-Release Systems (PQRS / BQRS)
- Hoist provisions, swivels, shackles, & rigging hardware
- 3D parametric CAD modeling, tolerance stack-ups, & CNC prototyping
HEC & NHEC SOFT GOODS DOCUMENTATION
Comprehensive product design and production-ready manufacturing drawing packages for certified airborne soft goods, synthetic rigging, and human restraint assemblies used in utility and rescue missions.
- HEC full-body harnesses, crew restraints, & adjustable lanyards
- High-modulus synthetic longlines, lifting slings, & protective jackets
- Detailed stitch-pattern layouts, thread specs, & webbing terminations
- Bill of Materials (BOM) structuring, labeling, & lot traceability
ROTORCRAFT ROLE EQUIPMENT & ASSEMBLIES
Industrial and mechanical product development for tertiary/auxiliary rotorcraft installations that expand pilot situational awareness, vertical-reference visibility, and multi-mission cabin utility.
- External cargo mirror assemblies & aerodynamic fairing enclosures
- Bubble observation window doors & vertical-reference provisions
- Auxiliary utility mounts, brackets, & cabin/cockpit role equipment
- Ergonomic field-of-view studies & airframe interface packaging
STC MANAGEMENT & DAR / DER COORDINATION
End-to-end project management guiding products from initial concept through Supplemental Type Certificate (STC) and PMA approval—coordinating directly with external regulatory delegates and airworthiness authorities.
- STC project planning, schedule management, & certification data packages
- External coordination with TCCA DARs, FAA DERs, & Approved DAOs
- Direct liaison with TCCA, FAA, & EASA certification specialists
- Test plan preparation, rig fixture design, & conformity inspection prep
PRECISION DESIGN ACROSS HARD GOODS, SOFT GOODS, & ROLE EQUIPMENT.
Every component is developed for manufacturability, operator ergonomics, and seamless progression through external DAR/DER and authority review. Explore our three core product design pillars below.
HEC & NHEC HARD GOODS PRODUCT DEVELOPMENT
Specialized industrial and mechanical design for external load hardware—including cargo hooks, hoists, primary/backup quick-release mechanisms (PQRS/BQRS), and rigging interconnects. Designed for anti-fouling geometry, gloved-hand ergonomics, and straightforward field inspection.
HEC & NHEC SOFT GOODS & HARNESS DESIGN
Complete product development and manufacturing drawing packages for human harnesses, synthetic longlines, lanyards, and cargo nets/slings. We translate operational field requirements into controlled textile specifications ready for certified cut-and-sew production.
AUXILIARY ASSEMBLIES & ROTORCRAFT ROLE EQUIPMENT
Product design and STC modification packages for tertiary and auxiliary rotorcraft equipment—enhancing vertical-reference visibility, cargo hook monitoring, and cabin utility without compromising airframe ergonomics or maintenance access.
DISCIPLINED PRODUCT DEVELOPMENT FROM CONCEPT TO STC APPROVAL.
We manage the complete design and certification workflow—delivering mature CAD, prototypes, and manufacturing packages while coordinating formal substantiation with accredited DARs, DERs, and regulatory authorities.
OPERATIONAL REQUIREMENTS & STC PLANNING
Definition of mission requirements, operator ergonomics, airframe interface geometry, and regulatory certification basis in alignment with project DARs/DERs and authority guidelines.
3D PRODUCT DESIGN & MANUFACTURING DRAWINGS
Detailed parametric CAD modeling, mechanism kinematics, soft-goods stitch layouts, tolerance stack-ups, Master Drawing Lists (MDL), and Design for Manufacturability & Assembly (DFM/DFA).
PROTOTYPING, FIT CHECKS, & TEST COORDINATION
Vendor management for CNC, sheet-metal, composite, and textile prototypes; aircraft fit-checks; test fixture design; and coordination of conformity and qualification testing.
DAR / DER SIGN-OFF & AUTHORITY ACCEPTANCE
Compilation of Installation Instructions, ICA, and Flight Manual Supplements, working seamlessly with external DARs, DERs, DAOs, or directly with TCCA, FAA, and EASA specialists through final approval.
READY TO DEVELOP YOUR NEXT AERONAUTICAL PRODUCT OR STC?
Lightyear Aero Inc. provides specialized product design, drafting, prototyping, and STC program management for rotorcraft role equipment and HEC/NHEC hard and soft goods. Mutual NDAs are executed prior to technical disclosure.
REGULATORY & COMPLIANCE NOTE: Lightyear Aero Inc. operates strictly as an industrial and aeronautical product design and project management consultancy. Formal airworthiness substantiation, compliance sign-offs, and regulatory findings are performed externally by accredited Design Approval Representatives (DARs) and Approved Design Organizations (ADOs) under Transport Canada Civil Aviation, or by Designated Engineering Representatives (DERs) and Designated Airworthiness Representatives (DARs) under the Federal Aviation Administration, or directly by specialists within Transport Canada Civil Aviation (TCCA), the Federal Aviation Administration (FAA), and the European Union Aviation Safety Agency (EASA).