Our Assembly and Testing Solutions in Aerospace and Defense
For over ten years, Sonplas has been developing high-precision test systems and assembly equipment for the aerospace and defense industry, designed to reliably test safety-critical components under extreme conditions while meeting the highest requirements in terms of process reliability, regulatory compliance and traceability.
In the aerospace and defense industry, precision, process reliability and full traceability are essential. Systems must operate reliably over the long term, even under extreme pressure, temperature and environmental conditions.
We develop test systems and assembly equipment for aerospace and defense, precisely tailored to safety-critical components and regulatory requirements. For over ten years, we have been implementing MRO test systems in particular, especially for fuel and hydraulic systems in the aerospace sector.
Test systems and assembly equipment for aerospace and defense
MRO test systems for maintenance, repair and operations
ATEX- and IECEx-compliant test bench solutions
Applications for fuel and hydraulic systems
Assembly systems for the defense industry
Climate chamber and high-pressure testing
Experience from over ten years of aerospace projects
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Matthias Kraml and Florian Klimmer: “Let’s talk about your project!”
Contact us without obligation and tell us about your requirements. Together, we will develop the right solution—technically sound and precisely tailored to your needs.
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Why Sonplas
is your ideal partner in aerospace and defense
Testing and assembly from a single source
Our systems combine assembly and testing processes into integrated system solutions. This reduces interfaces, increases process stability and ensures clear responsibilities – especially for complex MRO applications.
Cross-industry expertise
We leverage over ten years of experience in aerospace engineering and transfer this expertise specifically to applications in the defense sector. This results in robust concepts for safety-critical systems.
Flexible test systems with combined testing methods
Our test systems can combine multiple testing methods and procedures within a single platform – ranging from flow and pressure testing to environmental and functional testing. A typical test system for aerospace fuel systems must be capable of precisely mapping variable flow rates and high-pressure ranges.
ATEX- and IECEx-compliant design
For hazardous areas, we develop SIL-compliant (Safety Integrity Level) ATEX test systems for aerospace as well as IECEx-certified test systems. We support you from the initial concept through to safe and reliable operation.
Automated process for reproducible results
Our test systems execute predefined test sequences fully automatically. This minimizes operator influence, increases reproducibility and ensures complete traceability.
Which solutions do we implement for aerospace applications?
Our MRO test systems for maintenance and repair are used in aerospace applications for a wide range of fuel-carrying components, including:
- Servo valves and solenoid valves
- Fuel nozzles
- Pressure regulators
- Fuel rails
- Injection and pre-feed pumps, such as main fuel pumps, canister pumps, wing and center tank pumps, APUs, jettison pumps, as well as oil lube and scavenge pumps
Left: Pressure test bench
Center: Test bench for main fuel pump
Right: Fuel component test bench
For particularly sensitive applications, we implement, for example, test systems for fuel nozzles in aerospace. These allow you to validate flow rates, pressure behavior and leak-tightness under realistic operating conditions. In addition, we develop test systems for hydraulic components in the aerospace sector, capable of precisely simulating high-pressure ranges and variable load profiles. Combined with climate chambers, this results in climate test systems for aerospace components, enabling realistic simulation of temperature, humidity and other environmental conditions.
As these components are often larger in aerospace applications, test pressures and flow rates increase accordingly. Our systems are designed to accurately and safely handle these demanding conditions.
We are also the right partner for the assembly and testing of electronic components and assemblies, such as ECUs and FADECs.
Project example: Main Fuel Pump Boeing 777
Challenge:
A 30 kg main fuel pump with a flow rate of 650 liters per minute must be tested safely and reliably.
Our solution:
- Automated test process including intelligent component recognition
- Integration of up to 15 different engine variants
- Combination of pressure, flow and functional testing
- High-precision measurement in accordance with customer-specific CMM requirements
Standards, satety and traceability
What matters most?
In safety-critical industries, compliance with standards and complete documentation are essential.
Our test systems are designed to meet aerospace-specific requirements such as SIL, Component Maintenance Manual (CMM) specifications, as well as ATEX and IECEx directives, depending on the application. All test parameters are recorded, archived and stored with full traceability.
The result: systems that are not only technically robust, but also fully compliant with regulatory requirements.
Our focus is on custom-developed assembly and test systems for the maintenance of components in hydraulic and fuel systems.
Precision, process reliability and dependability are key requirements in the aerospace and defense industry. Especially in the maintenance of safety-critical systems, testing and assembly solutions must deliver reliable results under realistic conditions. In this interview, Sales Engineer Matthias Kraml explains how Sonplas leverages its aerospace expertise and applies it to demanding applications in defense and security.
Expert interview with
Matthias Kraml
Conventional fuels, Aerospace
Mr. Kraml, Sonplas has been active in the aviation industry for over ten years. What is your main area of focus?
Matthias Kraml: Our focus is on custom-developed assembly and test systems for the maintenance of components in hydraulic and fuel systems, particularly in the field of Maintenance, Repair and Operations (MRO). These systems must operate with absolute reliability. Our solutions enable precise functional testing under realistic conditions and are precisely tailored to the specific requirements of our customers.
What would you say is the biggest difference between aerospace sector and other industries?
Matthias Kraml: In aerospace, components are often one size – or several sizes – larger (laughs). They operate under higher pressures, temperatures and flow rates. At the same time, many components – such as valves, pumps or regulators – follow similar fundamental operating principles. With over ten years of experience in the aerospace industry, we leverage this know-how and transfer it specifically to applications in the defense sector.
In what ways do you assist your customers throughout the system development process?
Matthias Kraml: At the beginning, there is always a well-founded feasibility study. Together with the customer, we evaluate how a test system can be implemented in a technically and economically viable way. In parallel, we conduct product tests to align the test environment as closely as possible with the actual requirements of the components. This creates a solid foundation for a high-performance and reliable system.
What specifically sets your testing systems apart?
Matthias Kraml: Our systems are designed with a high degree of flexibility, enabling the testing of various components and pump types under realistic operating conditions. Pressure, temperature and flow can be precisely controlled, ensuring reproducible results and consistently high quality. Each solution is engineered to integrate seamlessly into existing processes.
What do you aim to achieve with every new system you develop?
Matthias Kraml: Flexibility, efficiency and precision. Only a test system precisely tailored to the application enables the reliable long-term operation of complex systems. Especially in aerospace and defense, where safety is paramount, this is crucial. That is what we stand for at Sonplas.
How do you benefit from our assembly systems in the defense industry?
In the defense industry, we focus on the development of assembly systems with a high degree of scalability. This enables the establishment of flexible production capacities and strengthens European value creation in the defense sector. In light of increasing demand and a dynamic security landscape, the ability to efficiently scale production volumes is essential.
Our assembly systems for the defense industry combine maximum productivity with absolute reliability, ensuring that all relevant quality and safety standards are consistently met. The result is future-proof manufacturing solutions that can be adapted at any time to new requirements and production volumes.
How do our testing solutions advance your capabilities in the defense industry?
Our test applications help you test complex components and systems with precision, safety, and traceability. We consistently meet the defense industry’s strict safety requirements and standards to ensure maximum reliability at every stage of testing.
The systems are designed to integrate seamlessly into various production environments, from the development phase through to series production, and to scale flexibly with your capacities.
This provides you with accurate and reproducible measurement data and stable processes that ensure your quality and safety in the long term.
Left: Inverter test bench
Center: Rotor assembly
Right: Test bench for main fuel pump
A strong partner
Our partnerships
The BDSV represents the interests of the German security and defense industry both nationally and internationally. With a strong network, it connects companies with policymakers, institutions and markets, thereby strengthening the competitiveness of the sector.
The TechHUB SVI brings together companies from the security and defense industry with research institutions, start-ups and cross-industry partners. Its goal is to foster innovation and enable new collaborations.
Here you can learn more about our cooperations and partnerships erfahren.
Sonplas is a member of BDSV and TechHub SVI.
Do you have any questions? Contact us.
Our references
Solutions that speak for themselves!
We understand what drives our customers
Frequently asked questions in aerospace and defense
Thanks to our many years of experience and numerous successful projects we understand what drives you!
Which components can be tested with Sonplas test systems?
Our test systems are suitable for a wide range of fuel-carrying components and assemblies. These include, among others, main fuel pumps, center and wing tank pumps, fuel nozzles, pressure regulators and relief valves. Complex assemblies and complete systems can also be tested – each solution tailored to the specific application.
Our tests must reflect real operating conditions. Can your test systems also simulate climatic conditions?
Yes. In combination with climate chambers, parameters such as temperature, humidity, air pressure and even vibration can be simulated. Depending on the application, additional environmental conditions can also be considered.
This allows components to be tested under realistic operating conditions – a crucial aspect for aerospace applications.
We have to comply with numerous standards and regulations. Are Sonplas test systems designed for this?
Our systems are designed in accordance with common industry and aerospace standards. This includes, in particular, aerospace-specific requirements such as Component Maintenance Manual (CMM) specifications as well as – depending on the application – ATEX and IECEx directives. Additional regulatory requirements are integrated on a project-specific basis.
We develop components for safety-critical applications. What qualifies Sonplas for projects in the defense sector?
Our experience in aerospace is a key advantage in this context. Many of the technologies and methods we apply there – for example in quality assurance, traceability and documentation – are specifically transferred to projects in the defense industry. The result is safe, compliant and field-proven test systems and equipment.
