Lessons From Working With NASA: Inside the Unique Challenges of the Aerospace Industry

Q&A with Americase’s Derrick Cunningham, Director of Innovation and Engineering 

Question #1: What unique challenges does the aerospace industry present when it comes to protecting mission-critical equipment?

The aerospace industry presents a lot of unique challenges when it comes to protecting mission-critical equipment. It’s one of the few industries that’s highly concerned about weight, for example, and uses materials that are constantly subjected to compression and decompression. The hardest part of managing aerospace products is that they experience consistent wear and tear. These items are used and abused frequently, with thousands of flights daily worldwide. Equipment isn’t always handled with care, which subjects aerospace products to more abuse and wear than almost any other industry. Even compared to fields like oil and gas, which are also rough on equipment, aerospace products undergo constant wear. Therefore, we have to design these products with much more structure and longevity in mind. Additionally, aerospace is very particular about how long something lasts because of the tight margins and high costs.

When clients invest in a case or a protective device, they expect it to last. This is the basis of the ATA 300 standard, which was developed specifically to test the longevity of items in the field. Airlines initially used various cases and containers to transport equipment, but they soon realized many items only lasted for a few flights or weeks, causing a logistics nightmare. To solve this, the ATA 300 standard mandates that cases last for a minimum of 300 round trips without a broken latch or other issues.

At Americase, we design products to withstand rigorous use and various environmental conditions. These items don’t stay in one environment; they move from extreme cold to heat, high humidity, and rain. We design with these factors in mind to ensure durability and performance.

Question #2: How does Americase ensure that its protective solutions meet the rigorous standards of agencies like NASA?

Americase works with NASA and other major players in the aerospace industry, often testing far beyond required standards. We consult with customers on their specific performance needs and aim to exceed those expectations. For example, if a product must withstand a certain number of Gs (gravitational forces) before sustaining damage, we design it to handle even more than required. We conduct testing both in-house and through partnered labs, covering scenarios like drop testing, vibration, environmental testing (rain, wind, sandstorms), and more. Some companies rely on qualification by design, assuming new cases will perform like past designs.

Question #3: What innovations or expertise has Americase brought to its aerospace clients to prevent failure in extreme conditions?

Americase provides significant innovation and expertise to its aerospace clients to ensure survival of their cases and cargo they protect in extreme conditions. Each component, from welded or riveted corners to latches, is carefully designed to work as part of a whole system. For example, with helicopter blade cases or long cases that can flex – many existing cases are bolted together with 20 to 100 bolts to prevent flexing. However, aerospace clients value speed and want quick access, not the hassle of removing and reattaching bolts.

To address this, we designed interlocking tabs in the lid, which prevent shearing and add structure without the need for bolts. By itself, a tab may not seem innovative, but combined with our corner and latch designs, it becomes part of a unique innovative solution.

We consider the complete customer experience, aiming to provide a case that is easy and efficient to use. We don’t want clients to feel like the case is a burden, needing extensive time to open or close. Our goal is for the case to be a solution, not a pain point, addressing the customer’s existing challenges.

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