Helicopters involved in life-saving missions are being continually updated with the latest equipment. This means that the installation of new kit can cause the configuration of the cabin interior to change. In such circumstances, this demands adjustments to the sound insulation blankets.

For this particular project, the sound insulation blankets in the Cobham AgustaWestland helicopters had been modified numerous times to accommodate new equipment, so they needed replacing. Unfortunately, a replacement product for this model of aircraft from the original manufacturer wasn’t an option due to the unique configuration of the interior, which meant that the operator had to source an alternative solution.

Cobham Helicopter Services contacted Starling Aerospace to see if they could provide a bespoke solution to fit the shape of the helicopter interior and the upgraded equipment. The operator also needed to ascertain whether a more sustainable solution existed for a sound insulation blanket, which could be easily modified with future upgrades.

With all the necessary CAA and EASA approvals in place for every aspect of aircraft cabin interior refurbishment, Starling Aerospace was very confident that it could provide a solution. To meet the exacting requirements, a new material needed to be developed which could be moulded around the contours of the helicopter cabin, as well as providing good sound insulation and an effective vapour barrier. The material also needed to be highly durable, easily cleaned and meet fire regulations.

Starling Aerospace developed the material using its in-house manufacturing facility, which includes the capability to undertake flammability and toxicity testing.  The company replicated the same thickness of foam density as the original sound insulation blanket from the helicopter. The material was then tested for durability and liquid absorption, to ensure it would not encourage condensation build up inside the helicopter, so it could be easily cleaned. Flammability testing was also carried out in-house to ensure the new material would meet stringent smoke density and heat release certification requirements.

Once it was fully satisfied that the new material would pass certification, Starling Aerospace sent a team to pattern the helicopter interiors. Each one had a different layout according to the equipment installed and therefore required careful measurement. Using this information Starling Aerospace’s expert team of fitters and seamstresses were able to produce tailor made quilted insulation blankets for each helicopter.

Under its CAA Part 21J and 21G EASA approvals Starling Aerospace produced service bulletin and modification documents for the new insulation blankets. The team then assisted Cobham Helicopter Services with the installation of the blankets under its 145 EASA approval.

For any rotary wing interior projects, please Contact Us.