Moving and Shaking Aviation Through Reverse Engineering An Interview with Aviation Specialties

An Interview with Aviation Specialties 

By Annamarie Buonocore 

As an editor with In Flight USA Magazine, I have the privilege of meeting the movers and shakers in the general aviation industry on pretty much a monthly basis. These professionals and companies are not just good at what they do, but they are exploring with new technologies, including UAS, 3D printing, and reverse engineering to expand their services. They give us hope for the next generation of private aviation. One such company is Airmotive Specialties based at the Salinas Airport in Salinas, Calif. 

I first heard about the interesting new work of Airmotive Specialties from a friend and In Flight USA contributor on Facebook. That was when I knew I had to stop in and check it out on my next round of deliveries. 

When one walks in on an ordinary day, Airmotive Specialties appears to be a regular shop for aviation maintenance, but when I walked in, the staff was deeply involved in a training session on using new 3D and reverse-engineering technologies. Feeling awkward, I turned toward the door, but the kind owners, Dave and Mari Teeter, offered me a tour of their facility and gave me the following interview. It was an enthralling experience to say the least. 

IF: How long have you been doing this and how long has Airmotive Specialties been in business? 

AMS: I started Airmotive Specialties in January of 1999, but I have been in aviation much longer. I was working with my dad since I was 10.

IF: How long have you been a pilot? 

AMS: I got my student license when I was 15, but I started flying when I was a baby with my father. I have been fixing and restoring old and broken airplanes since I was 10 or 12. 

IF: What is this reverse-engineering concept? 

AMS: We got into warbird restoration several years ago. We developed processes to be able to do one-off manufacturing. We manufacture parts, mainly for P-51 Mustangs. The need for reverse engineering has really grown due to the low volume of airplanes being produced. There are many older aircraft that are still being flown, but they are so old that the manufacturers no longer support them. Or if they do support them, the options are so costly that people are looking for alternatives. With that, insurance companies and others have had us look into what we can do to keep the legacy fleet flying. We really enjoy WWII aircraft, and we had some very unique requests over the last few months. Reverse engineering is all the way into the airline industry, and it is really growing. That is the training going on today. We are being trained by a Canadian company on how to use the 3D scanners. We are replicating older parts through 3D scanning and printing to keep older planes flying. This has helped us grow from 12 employees a couple of years ago to about 20 employees today. That is how we got into it. Insurance companies wanted us to look into options for obtaining new parts to make these planes safe to fly. 

IF: What is a good example of a time when you used reverse engineering? 

AMS: A good example is the Rockwell 114 Commander, a single-engine airplane. A gentleman had a damaged aileron, and he could not fly this plane with a damaged aileron. Nobody could get another aileron for him. Nobody had the time or ability to make the skins. Because of our processes to do one-off items, we were able to save the skin and get the airplane flying. 

IF: What is parts fabrication? 

AMS: Parts fabrication is making whatever part you need. For example, if you need a wing, we manufacture whatever parts we need to build that wing. We make the parts to make hinges and other needed items. There is very little 3D manufacturing going on in the aviation industry now. I think it’s a growing industry that is going to be huge with us. In order to manufacture parts for an airplane and sell them on the mass market, you have to have a parts manufacturer and get approval from the FAA. We have been working under the FARs that allow us to manufacture just one part at a time. Eventually, we will gain parts manufacturing approval, and we will be able to produce mass parts. We are working with the FAA now to get that certification. 

IF: Is the scanner a new invention? 

AMS: No, it is not a new invention. This company who made it has been making them for a while, but they told us just a few days ago that there are only three companies in California that are using this technology. It is really going to revolutionize the restoration business. 

IF: What are your concerns going forward? 

AMS: They don’t have the materials down. When you are reverse engineering something, you have to show that you are making it equal to the other part. You have to have a whole different approval to make the part different. That takes longer and costs more money. That is why 3D printing is moving a little slower than reverse engineering. I think we are about 10 years away. We have 3D printed some stuff from museums—things that didn’t have to fly. It worked very well. 

IF: Is the scanner really big? 

AMS: No, it fits in a suitcase. It’s small and handheld. 

IF: Is it difficult to use? 

AMS: No, it’s not. The only difficulty in it is the drawing. When you are reverse engineering something, you have to draw the part first. You have to know how to use the software so that you can get the accurate thickness and dimensions. We are being trained on the software now so that we know how to achieve that accuracy. The drawing is pretty intense. 

IF: How much does the scanner/technology cost? 

AMS: A lot. I have over $100,000 invested in this. 

IF: How much do you charge the client for this service? 

AMS: If there are travel costs, we charge for that. That might be the case for a museum or something. But to come to us, it’s not that expensive. It’s really not. The laser scanner scans at a high rate, which is a huge plus for this new scanner. I can do a part starting from scratch in about 30 or 45 minutes. With the inspection software, we can achieve more accuracy, and it’s an added bonus. 

IF: That answers my questions. Thank you! 

Airmotive Specialities is here to help you with your older aircraft and warbirds. They can be contacted at 831/757-7154.