Engineering / Introduction

MAGE offers the complete industrial design, manufacture, installation and certification of fixed and rotary wing aircraft interior modifications and components for VIP, corporate and commercial airline operators.  

 

We provide turnkey solutions through a comprehensive, flexible and price competitive service. Our team of specialists design, manufacture and install complete aircraft interiors and interior systems (mechanical and electrical). This includes airworthiness approval, new build, modification and refurbishment for a wide range of interior products.

 

We have also completed a variety of VIP and Head of State aircraft interiors for both fixed wing and helicopters.

 

 

 

 

 

 

 

 

Under our EASA Part 145 maintenance approval, we provide refurbishment, repair and maintenance services, all on site.

 

Our project managers together with their dedicated Interiors team make every effort to ensure your programme is completed on time, on budget and to specification.

 

 

 

 

 

 

 

 

 

 

 

 

 

MAGE have the approvals to repair and modify in-service equipment. Our approvals include:

 

• EASA part 145 approval
• EASA part 21J  and G approved
• CMM/IPC and SB to ATA 100 standard

 

 

 

 

 

 

 

 

 

 

 

 

Modifications include the integration of mechanical, electrical and infrastructure solutions for the whole airframe and interior.

 

• Avionics
• Electrical checks, modification and manufacture
• Incorporation of SBs
• Furnishings
• Complete interior refurbishments

 

 

 

 

 

 

 

 

 

 

MAGE can provide the modification of In Flight Entertainment to existing systems, as well as the design, manufacture and installation of turnkey solutions. These include:

 

• DVD
• Nintendo/XBox
• CD
• MP3
• Airshow
• Satcom
• Intercom

 

 

 

 

 

 

 

 

MAGE operates an on-site clean room and spray booths. We can offer all types of paint finishes, including:

 

• Water based
• NEXTEL systems
• Mankiewicz flip-flop

 

We have extensive experience in providing a wide range of trim finishes, including:

 

• Application of real wood veneers
• Laminates
• Fabrics and silks
• Upholstery fabrics and leathers (including covering/recovering)
• Curtains

 

 

 

 

 

 

MAGE can design, manufacture and install interiors for a wide range of airline and private fixed wing and rotary aircraft.

 

Our industrial design capabilities include CAD 3D (AutoCAD and Inventor) and we have in-house manufacturing facilities that include composite metalwork, electrical design and manufacture, soft trim and paint finish.

 

We also manufacture and supply mock-ups for crew training or visual development, including modular demountable galleys and other role equipment to your own unique specifications.

 

 

 

 

 

 

 

 

One of the unique features about MAGE is that we have the facilities and the expertise on site at Fairoaks to offer a complete Interiors service.

 

From January 2006 this will also include a new purpose built Interiors Workshop.

 

 

 

 

 

 

 

 

 

 

 

 

MAGE installation includes all tests and controls for stress, flammability and safety – we are certified to handle these in-house.

 

Installation also covers the integration of In Flight Entertainment systems, the design, manufacture and installation of electrical looms, as well as bespoke and specialist products.

 

Working alongside our programme management we maintain one project team for the airframe and prefit.

 

 

 

 

 

 

 

Our Interiors work covers everything from seating configurations (including VIP) to structural modifications. This covers a wide range of interior products, including:

 

• Galleys
• Stowages
• Bulk Heads
• Wardrobes
• Crew Rests
• Lavatory Compartments
• Dog Houses

 

 

 

 

 

 

 

 

MAGE is approved to provide bespoke solutions for a wide range of aircraft, from the size of a Boeing 747 to a Cessna 412. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mann Aviation Group Engineering prides itself on the quality of our work and our staff. We are fully qualified and accredited, with the following approvals:

 

Airworthiness Approvals

 

Design

 

• UK CAA E1/E2/E3/EASA
• EASA  part 21 (JA) DOA
• UK MOD, Design Approval for Aircraft and Airborne Equipment

 

Manufacture

 

• EASA part 21 (GA) POA

 

Maintenance

 

• UK CAA 145/C6
• UK CAA Air Navigation Ref AD/1782/92
• UK CAA Avionics 00043

 

 

Additional Approvals

 

• Bell Helicopter CTF Pilot & Maintenance
• Bell Helicopter Customer Support Facility
• Bell Helicopters Factory School (flying and engineering)
• UK MOD List X Company
• BS5750 Part 1/ISO9001/EN29001
• DAOS Design Approval
• EASA part 145 Maintenance
• FAA Approved Repair Station
• EASA FLC 2 Licensed Airfield
• EASA part 147 Training School
• EASA Flying Training Organisation Fixed & Rotary Wing
• Bermuda DCA (Approved Repair Station)
• Westlands
• EASA Flying Training Organisation

 

 

Avionics

 

With over 36 years’ experience of avionic installations, maintenance and modifications, MAGE offer the highest levels of quality and expertise in relation to a wide variety of fixed wing and rotary aircraft.

 

Our dedicated Avionics Division covers all areas of avionics for both the civil and military sectors of the industry in the UK and overseas, including the provision of working parties for off-site activities such as modifications and aircraft surveys. We offer both line and Equipment Repair capability, as well as a Composite Component Repair Facility.

 

Our work is carried out within the scope of the Company EASA Part 21 and EASA Part 145 approval.

 

In addition, MAGE designs and markets a wide range of aviation related products, including:

 

• Flat screen LCD colour monitors (NVG compatible if req’d)
• In Flight Entertainment
• Ground based DME beacon
• Helicopter camera mounts
• Stretcher installations
• Control consoles
• Bespoke camera installations for aerial surveys
• NVG compatible cockpits
• Cables and looms

 

 

We are authorised dealers for the following manufacturers:

 

• Garmin
• Bendix King
• Rockwell Collins
• Universal Avionics
• Ryan International / Avidyne
• Honeywell 

 

MAGE’s Products department is responsible for all Flat Screen Monitor related work. This is carried out in a self-contained workshop with a built-in positive pressure clean room.

 

We work in partnership with operators to ensure optimum performance standards. Our current range of monitors include the following features:

 

• Ruggedised for aircraft operation
• Very high bright screen, typically > 870 Cd/m2
• High resolution
• Internal daylight and NVG compatible screen illumination via a front panel switch
• Computer Graphic and multiscan video image handling

 

 

In Flight Entertainment

 

Audio International (AI) the Decrane In-flight Entertainment specialists have appointed MAGE as the Service Centre and distributor for their equipment in Europe.

 

Our technicians have undergone a comprehensive training programme at the AI main facility in Little Rock Arkansas to enable the implementation of a full service centre in Europe and support of AI equipment and installations. 

 

The facility, which went live last Autumn, handles repair, warranty support and equipment sales for users and operators.

 

We see the relationship with AI as a stepping stone to providing an extension to our comprehensive interior installation and upgrade packages which include full IFE capability for new and in service aircraft.  The comprehensive avionic design and certification capability that we hold enable us to offer a turn key package for VIP interiors.

 

Our avionics section workshop is responsible for the distribution and repair of IFE equipment. This work includes:

 

• Distributing IFE within Europe on behalf of Audio International
• Repairing and overhauling IFE equipment
• Carrying out all work within the scope of the Company EASA Part 145 approval

 

 

 

We manufacture cables and cable loom assemblies within our avionics workshop. The work includes:

 

• Designing and manufacturing cables and cable loom assemblies to aircraft specification. (We are CAA approved for cable loom manufacture)
• Repairing and overhauling cables and cable loom assemblies
• Carrying out all work within the scope of the Company EASA Part 21 and EASA Part 145 approval
• Manufacturing cables for the UK MOD

 

 

 

 

MAGE has enormous experience of NVG modifications. We are currently the only company in Europe to have a civilian aircraft fully certified to operate with NVG and have extensive experience of Night Vision Imaging Systems (NVIS) on UK and European Civilian registered aircraft.

 

Our Night Vision work is carried out in a self-contained workshop within our avionics section. This section works closely with OEMs in the production of solutions and modifications to aircraft and equipment for NVG compatibility. The work includes:

 

• Modification to OEM equipments for NVG compatibility
• Assistance in the design of complete cockpit modifications
• Production and installation of compatible equipment in aircraft
• Testing of NVG compatible components and cockpits
• Production of NVG related manuals and documentation
• Provision of NVG modification kits to UK and foreign MOD units

 

 

 

 

 

 

Mann Aviation Group Engineering (MAGE) provides expert maintenance, repair, overhaul, modification and support services for a wide range of civilian and military fixed wing aircraft. Our scheduled maintenance work covers everything up to CofA renewals.

 

MAGE engineering personnel have been carefully selected for their comprehensive operational and heavy maintenance experience on our customers’ aircraft. They are drawn from military, civil and oil and gas support based industries. It’s the quality of our people and our work that has enabled us to build up an unrivalled reputation over the last 36 years. Our capabilities include:

 

• Generating solutions for each individual aircraft requirement
• High percentage of licensed engineers to cover large capability list
• CAA approved pilots to carry out handling and CofA air-tests
• NiCad and lead acid battery shops
• CAA, FAA, EASA, Bermudan approvals

 

 

MAGE fixed wing aircraft maintenance work includes:

 

• Twin Commander authorised service centre, including major repairs
• Piper aircraft maintenance – all types
• Cessna aircraft maintenance up to Citation series
• Beechcraft aircraft maintenance up to Kingair series
• Single Commander aircraft maintenance
• Twin Otter Jigs
• DO 228
• Additionally we have scope for many more types

 

 

In addition, we have extensive experience of working with the following engine types:  Lycoming, Continental, Pratt-Whitney, Garrett Engines.

 

 

 

MAGE fixed wing maintenance services include:

 

• All types of repairs (minor to major structural repairs)
• Worldwide support across all continents (including Antarctica)
• Sheet metal / structural engineering
• Engine overhaul
• De-icer boot replacements / repairs
• Windshield replacements
• Aircraft recovery and repair evaluations
• Calibration facilities for fuel quantity, weighing, torque, pressure etc
• Pressure tests
• Battery servicing
• Supply of spares and technical records
• All major inspections
• Approved Class 1&2 compass bases

 

 

 

 

MAGE modification packages cover major structural repairs, including:

 

• Bell 206 approved airframe and tail boom jigs
• Twin Otter repairs – wing, fuselage, flying controls
• DO 228 major repairs and modifications
• Camera hole modifications to all types of pressurised and unpressurised aircraft, including DO 228, Twin Otter, Beech, Piper, Cessna, Twin Commander

 

 

 

 

 

 

 

 

 

Mann Aviation Group Engineering (MAGE) provides expert maintenance, repair, overhaul, modification and support services for a wide range of civilian and military helicopters and auxiliary equipment. Our scheduled maintenance work covers everything up to CofA renewals.

 

MAGE engineering personnel have been carefully selected for their comprehensive operational and heavy maintenance experience on our customers’ helicopters. They are drawn from military, civil and oil and gas support based industries. It’s the quality of our people and our work that has enabled us to build up an unrivalled reputation over the last 36 years. Our capabilities include:

 

 

 

 

 

 

 

MAGE is an EASA Part 145 approved maintenance company and FAA approved repair station. Our helicopter maintenance work includes:

 

• Bell & Agusta Bell - B47; B206; B407; B212; B412; B430
• Agusta - A109A; A109II; A109C; A109E Power; A109S Grand
• Eurocopter - AS350; AS355; AS365 Dauphin
• Sikorsky - S76A; S76C

 

 

 

 

 

 

 

 

 

 

MAGE helicopter services include:

 

• Line maintenance and ramp support services
• Base maintenance and defect rectification
• Modifications and service bulletin embodiment
• Structural repairs
• Bell 206A/B fuselage and tail boom repair fixtures
• Agusta 1200hr maintenance and transmission / gearbox ‘special inspections’
• NiCad and lead acid battery servicing
• Interior customising
• Supply of spare parts and materials
• EASA certification and approvals
• Customisation, including VIP interiors
• Supply and installation of OEM supplied installation kits
• Supply and installation of STC/PMA approved accessories
• Interior design, manufacture and installation
• Interior and exterior completions

 

 

 

MAGE modifications include:

 

• Service bulletins
• Camera mounts (AS 350/355)
• Up & Downlink equipment
• Avionics
• Radio
• Radar
• Airborne Surveillance

 

 

 

 

 

 

 

 

MAGE has close working partnerships with key manufacturers and acts as the distributor for the following:

 

• Distributors for Air Comm Corporation Inc ( heaters and air conditioners)
• Suppliers of Aeronautical Accessories, including equipment
• Suppliers for DART Aerospace Ltd equipment
• Design, manufacture and supply of integrated aerial camera mounting systems
• Integration of microwave downlink equipment

 

 

 

 

 

 

 

MAGE operates under Design Organisation Approval (DOA). We are fully up-to-speed with EASA Part 21 DOA, enabling us to work on any European Community aircraft.

 

With regulations and systems in the industry changing at an increasing pace and with more of the technical decision making passing to EASA, we have been one of the first to respond to and embrace these changes.

 

Most of our design work covers modifications, including major repairs. Please click on the links shown here for further details.

 

 

 

MAGE currently holds the following approvals:

 

• Approved by the CAA under the UK Air Navigation Orders against BCAR’s chapter A8-8 groups E2 and E3, approval number DAI/1782/92
• Approved under BCAR Chapter A8-9 to conduct F3 flight tests under ‘B’ Conditions (G-83) which may be gained in conjunction with design tasks on an ‘as and when’ basis.
• Approved by the MoD DAOS scheme under approval number ALTG/07/03/11/09
• MAGE is registered with B.S.I. to BS EN ISO 9001 (2000) with registration number FM 25055
• EASA P+21G Approval Ref:UK.21.G.02247
• Approved by the FAA under FAR145 approval number M3VY380X
• EASA P+14S Approval Ref:UK>14S.00764

 

 

 

 

MAGE’s dedicated Design Office occupies approximately 5,500 square feet and includes 8 CAD workstations and an A1 plotter, all fully networked through a separate server.

 

Our main design tools include:

• AutoCAD
• Inventor 3D Modelling
• MathCAD 

 

We have a Technical/Drawing Library and keep a dedicated database to record information about projects.

 

We also operate a Design Assurance System which ensures that all products are designed in accordance with the applicable airworthiness requirements, certification specifications and environmental protection requirements.

 

 

 

Most of the work undertaken by MAGE’s Design Office consists of designing repairs and modifications, as well as performing independent assessments of a wide range of both fixed and rotary wing aircraft.

 

The work applies to existing aircraft airframe, electrical, flight control, radio and instrumentation systems, including any necessary changes in the associated documentation. Areas of modification may include:

 

• Surveillance equipment installations – camera, radar, FLIR, avionic system integration and operator consoles in fixed or role change mode
• Emergency medical services (EMS) and police installations
• Defence systems projects – major system integration and modification
• Cabin interior upgrades, including galleys, toilets, stowages and audiovisual systems
• Avionic equipment installations, including GPS, nav/comm equipment
• Repair schemes – design of repairs outside the SRM limitations, liaising with the aircraft manufacturer
• Airworthiness co-ordination with Design Authority

In order to accomplish our design modification work, we have extensive expertise in the following technologies:

 

• Night vision imaging systems, including the associated compatible cockpit/cabin lighting
• Advanced avionics, e.g. for the operation and control of camera and surveillance systems
• General avionics (navigational aids and communications etc)
• Fabrication methods using metal and composite materials
• CAD to facilitate the design of the modifications