Our Products Aerospace
aSonplas brings cutting-edge automation expertise from the automotive industry into the aviation sector: For over ten years, the machine manufacturer has supported the precise maintenance of fuel and hydraulic systems with innovative custom equipment. The individually engineered assembly and testing systems ensure exceptional process reliability: They are flexible, efficient, and precisely tailored to your specific requirements. This enables the implementation of customized system concepts for functional testing of components in the Maintenance, Repair, and Overhaul (MRO) sector.
What types of components are the assembly systems and test benches used for?
The aerospace industry uses fuel-carrying components similar to those found in the automotive sector. These include:
- Valves
- Injectors (fuel nozzles)
- Pressure regulators
- Fuel rails
- Injection and pre-feed pumps
Since these components are significantly larger in the aerospace industry than in the automotive sector, both pressure and flow rates are correspondingly higher.
What range of testing capabilities does Sonplas provide?
- We develop test systems for a wide range of fuel components—including pumps. These systems enable flexible test and environmental conditions for lifelike Based on customer-specific requirements, we perform hydraulic measurements of flow, pressure, and leakage.
- A single system can handle both air and liquid testing, while calibration cycles, blow-out, and flushing processes are fully automated.
- Jet test stands analyze the angle and width of the spray pattern emitted from the fuel nozzle.
- A climate chamber can simulate various environmental parameters such as temperature, humidity, and air pressure—with the option to incorporate vibrations as well.
- We conduct feasibility studies and product tests to assess whether a project or product can be realistically implemented from technical economic and organizational
- With our systems, injection rates can be accurately determined and temperatures reliably monitored.
- We provide functional and endurance testing for both individual components and complete systems.
- Testing of center and wing tank pumps is possible at flow rates reaching up to 900 l/min.
All tests and measurements are performed according to customer-specific requirements, following the CMM (Component Maintenance Manual) guidelines. Sonplas also runs its own in-house development laboratory.
Complete solutions from a single source – assembly and testing combined
As a special-purpose machine manufacturer, we design complete solutions for both assembly and testing. This minimizes interfaces and streamlines processes. We integrate off-the-shelf components where appropriate and rely on in-house developments when standard solutions fall short. The result: highly adaptable, cost-effective, and high-performance systems.
Working together toward the ideal testing process
We develop your system in close collaboration with you—tailored to your specific components, test requirements, and desired level of automation. Whether it’s a single component or a complete system, an existing line or a new installation, we deliver custom solutions that precisely meet your needs.
Outlook: Aviation, medical technology, semiconductors and more
The successful transfer of technology from the automotive industry demonstrates that our special-purpose machine solutions are scalable across a wide range of industries. This opens up new opportunities in other high-tech sectors such as medical technology, semiconductor manufacturing, and energy systems.
Your benefits:
We successfully apply our many years of experience with injection systems—from injectors to pre-feed pumps—to aviation applications. In the process, we draw on proven testing methods from the automotive industry and adapt them to meet the specific requirements of the aerospace sector.
Our systems test components such as fuel nozzles, pumps, and valves under realistic conditions—including combined air and liquid testing, leakage detection, and spray (jet) testing. Calibration cycles, flushing processes, and blow-out procedures can all be fully automated.
We develop test benches for use in environments prone to explosions, in full compliance with all relevant standards. From initial consultation to safe, reliable operation, we support you every step of the way.
Our test benches automatically identify test objects, self-adjust, and perform all testing steps fully autonomously. This reduces operator effort, enhances reproducibility, and minimizes potential sources of error.
When needed, we combine multiple testing methods within a single system. This allows for complete pump analysis, testing of individual components such as pressure relief valves—or both at the same time, depending on the specific requirements.
For the aviation industry, we automate key processes by leveraging our extensive experience from the high-volume automotive industry.
Case study: Main fuel pump testing for the Boeing 777
One customer presented us with a complex challenge—testing a 30-kilogram main fuel pump capable of delivering 650 liters per minute.
The solution:
- Automatic testing process with integrated component recognition.
- Full integration of up to 15 engine models
- Combination of pressure, flow and function testing
- High-precision measurement based on customer-specific CMM specifications
FAQ
What types of components can be tested with Sonplas test systems?
Our test benches are designed to handle a wide range of components—including main fuel pumps, center and wing tank pumps, fuel nozzles, pressure regulators, and pressure relief valves. Even complex assemblies and complete systems can be tested with precision.
What does “customer-specific” mean in relation to the test benches?
Instead of developing off-the-shelf products, we design custom special-purpose machines. Our testing systems are precisely tailored to your components, your testing requirements, and your specific spatial and process-related conditions.
Can the test benches simulate climatic conditions as well?
Yes. Using climate chambers, we can simulate temperature, humidity, air pressure, and even vibrations. This enables components to be tested under realistic conditions—an essential factor for aerospace applications.
Can existing test benches be retrofitted or upgraded?
Yes. We also support the optimization of existing lines and test benches. Working closely with you, we identify automation potential, enhance existing testing procedures, and boost both efficiency and process reliability.
Which standards and regulations do Sonplas test systems comply with?
Our systems comply with established industry standards and regulations, including aviation-specific CMM specifications as well as ATEX and IECEx standards. Upon request, we can incorporate additional regulatory requirements tailored to your specific project.
What flow rates and pressures can be tested?
Depending on project requirements, we design test benches capable of handling high flow rates—up to 900 liters per minute—and pressures in the high-pressure range typical of aviation. We flexibly scale our solutions to match your specific needs.
Contact us!
Our products in action
Fuel component test stand
Pressure test stand
Main fuel pump test stand
Matthias Kraml
Product Manager Aerospace
Sonplas has been active in the aviation industry for over ten years. What is your main area of focus?
Our focus is on custom-designed assembly and testing systems for maintaining components in hydraulic and fuel systems—particularly in the field of Maintenance, Repair, and Overhaul (MRO). These systems must operate with absolute reliability. That’s why our solutions enable precise functional testing under realistic conditions,delivered with flexibility, efficiency, and exact alignment to our customers’ specific requirements.
What would you say is the biggest difference between the aviation sector and the automotive industry, where Sonplas has its roots?
In aviation, components are often significantly larger—which also raises the demands in terms of pressure, temperature, and flow rate. That said, many of the parts—like valves, pumps, and regulators—are quite similar. We bring over 30 years of expertise from the automotive industry and apply that knowledge purposefully to aerospace applications.
In what ways do you assist your customers throughout the system development process?
We begin with a comprehensive feasibility analysis. In close collaboration with the customer, we assess whether and how a test bench can be implemented from both a technical and economic standpoint. This process draws on our full range of expertise in testing technology. At the same time, we perform product tests to optimally align the testing environment with the real-world requirements of the components. This approach forms the foundation for a high-performance, reliable system.
What specifically sets your testing systems apart?
Our systems are highly flexible, enabling the testing of various pump types under realistic conditions. Both pressure and flow rate can be precisely controlled,ensuring reliable results and consistently high product quality. Each customer receives a tailored solution that integrates seamlessly into their existing processes.
What do you aim to achieve with every new system you develop?
Flexibility. Efficiency. Precision. Because complex systems can only be operated safely over the long term with a precisely calibrated test system—especially in aviation, where safety is the highest priority. That’s exactly what Sonplas stands for.