February 05, 2025

Steven Bentley

Sofema Aviation Services (SAS) www.sassofia.com considers the key elements of the Aircraft Type Certification Process

Introduction

The development of a new aircraft type typically spans up to five years due to the complexity and rigour of the process. Modern aircraft designs incorporate advanced technologies and systems, necessitating extensive testing and refinement.

Regulatory compliance adds another layer of challenge, requiring thorough evaluations and iterative problem-solving. Ground and flight testing involves simulating hundreds of scenarios, including worst-case conditions, to ensure robust performance. Collaborative oversight from regulators introduces additional reviews and feedback, further extending timelines.

This resource-intensive effort involves large engineering teams, prototype manufacturing, and specialized test facilities, all with an unwavering focus on safety.

  • The aircraft type certification process is required to ensure that a new aircraft design meets all applicable airworthiness, environmental, and safety standards established by aviation regulatory authorities

Primary Authorities for Type Certification

  • European Union Aviation Safety Agency (EASA)
  • Federal Aviation Administration (FAA)
  • Transport Canada Civil Aviation (TCCA)
  • National Civil Aviation Agency of Brazil (ANAC)

This process is extremely complex and can typically take up to 5 years.

Conceptual Design Phase

  • Initial concept design by the manufacturer.
  • Preliminary discussions with the regulatory authority to outline the certification process.
  • Initial aircraft specifications and performance targets.
  • Definition of applicable regulatory requirements (e.g., EASA CS-25 for large aircraft, FAA FAR Part 25).

Application for Type Certification

  • Submission of the formal application to the relevant regulatory authority.
  • Assignment of a certification team by the authority.
  • Type Certification Basis: The agreed set of airworthiness and environmental standards.
  • Certification Plan: Detailed project timelines and key milestones.

Detailed Design and Development

  • Engineering and detailed design of the aircraft, including structures, systems, and avionics.
  • Selection of materials and components.
  • Creation of technical documentation.
  • Detailed design specifications.
  • Compliance documentation for initial reviews.

Compliance Demonstration

  • Extensive ground testing of components and systems.
  • Structural tests (e.g., static and fatigue tests).
  • System integration tests.
  • Avionics and software validation.
  • Flight test program to evaluate performance, handling, and safety.
    • Verification of takeoff, landing, and in-flight performance.
    • Testing of emergency systems.
    • Test reports and data.
    • Identification and resolution of issues.

Certification Review

  • Regulatory authority reviews the compliance data, test results, and design documentation.
  • Conducting additional inspections or tests as required.
  • Resolution of all non-conformities.
  • Finalized compliance documentation.

Issuance of Type Certificate

  • Approval of the aircraft’s airworthiness based on the review of compliance with all regulations.
  • Issuance of the Type Certificate, allowing production and operation of the aircraft.
  • Type Certificate (e.g., TC number, type design data).
  • Aircraft limitations and conditions for use.

Post-Certification Activities

  • Ongoing support and monitoring by the manufacturer.
  • Addressing any in-service issues or airworthiness directives (ADs).
  • Amendments to the type certificate as needed (e.g., for design modifications or new variants).

Industry Steering Committee (ISC) & Maintenance Review Board (MRB)

The Maintenance Review Board (MRB) plays a pivotal role within the regulatory framework for establishing, evaluating, and approving maintenance programs for new aircraft types.

  • Operating under the oversight of the Industry Steering Committee (ISC), the MRB follows guidance provided by the Policies and Procedures Handbook (PPH), which serves as the instruction set for ensuring compliance and standardization.
  • Rooted in the Maintenance Steering Group-3 (MSG-3) methodology, the MRB process systematically identifies maintenance tasks and intervals, optimizing the safety, reliability, and operational efficiency of the aircraft while ensuring alignment with regulatory expectations.

The Role of MSG-3 in the Context of Aircraft Certification (Type Certification)

MSG-3 (Maintenance Steering Group-3) is a cornerstone methodology for developing maintenance programs based on reliability and safety principles.

MSG-3 and Type Certification (TC)

  • Aircraft certification requires that the design meets regulatory safety and operational requirements, and part of this includes a robust maintenance program.
  • MSG-3 provides a structured framework to identify preventive maintenance tasks that minimize operational risk while ensuring economic efficiency.
  • As part of the type certification process, manufacturers must demonstrate compliance with safety regulations (e.g., EASA CS-25, FAR Part 25). MSG-3 is integral in the Maintenance Review Board (MRB) process, where maintenance tasks derived from MSG-3 analyses are validated and approved by the regulatory authority.
  • The finalized maintenance review board report becomes part of the Instructions for Continued Airworthiness (ICA).

Industry Steering Committee (ISC) and Its Role

  • The ISC provides a collaborative forum for Original Equipment Manufacturers (OEMs), operators, regulatory authorities, and other stakeholders to guide the development of the MRB report.
  • Reference to the ISC Policy and Procedures Handbook (PPH) (The PPH defines the roles, responsibilities, and processes for the ISC and its working groups. It ensures standardization and consistency in the development and approval of maintenance programs.)
  • The ISC ensures that the MSG-3-derived maintenance program meets both regulatory and operational expectations for safety, reliability, and efficiency.

System Safety Assessment (SSA)

  • The SSA evaluates system-level risks to ensure that aircraft systems meet acceptable safety levels. SSA results are used to:

>> Identify critical failure conditions.

>> Define safety-related maintenance tasks.

>> SSA supports the identification of Functional Failure Modes (FFM), failure effects, and mitigation strategies.

>> Tasks derived through MSG-3 are cross-referenced with SSA outputs to ensure alignment with safety objectives.

>> SSA ensures that risks identified during the MSG-3 process align with the failure classifications outlined in regulatory guidelines (e.g., CS-25.1309, FAR 25.1309).

Next Steps

Follow this link to our Library to find & download related documents for Free.

Please see the following course: EASA Part M – Understanding MSG 3 Methodology and Analytic Process Essentials, available as either Classroom or Webinar. For additional questions or comments, please email team@sassofia.com.

Share this with your network:

Tags:

FAA, SAS blogs, Certification Process, Transport Canada Civil Aviation (TCCA), Aircraft Type, Federal Aviation Administration (FAA), European Union Aviation Safety Agency (EASA), National Civil Aviation Agency of Brazil (ANAC), FAR Part 25