The term “Flight Hardware” is commonly used. When asked what constitutes “Flight Hardware” most people rattle off a similar list of requirements for objective evidence of tractability and surface coatings but where do these requirements come from.


Our commonly understood yet unofficial list of criteria for qualifying “Flight Hardware”:

Certificates of Conformance
Chemical Test Reports
Physical Test Reports
Manufacturers Lot Numbers
Passivation
Alodine or Anodize
Primer
Is there an FAA or other standard which defines a comprehensive list of official criteria to qualify something as “Flight Hardware?”

Generally it's all the stuff that actually flys including attached items

I did a quick search and couldn't really find a definition of Flight hardware. So, I would agree with Randy, that any hardware that could cause failure, crash, loss of life, loss of property (in the Aviation field) and anything that is used to assist in the overall in-flight function of the Aircraft, or Space Craft. The only thing that I think would not fall under any of my unofficial, undocumented, unsupported statements would be Ground Support Equipment (GSE).

The identification of what is considered “Flight Hardware” is usually within the body of the customer’s contract/PO, specifications or drawing. One that usually jumps out is “Manned Space Flight”.

Your list of unofficial criteria for qualifying “Flight Hardware” also apply to automotive, nuclear, food and drug, and medical sectors. These customer required documents do not realy identify this type of product in and by them selves. But to add to your list I would also like to suggest:

EASA Form 1, Airworthiness documentation used by the European Aviation Safety Agency (EASA).
Parts Manufacture Approvals (PMA) - FAA Approvals
Airworthiness Approval (8130) - FAA Approvals
Transport Canada Form 24-0078 – Canadian equivalent to FAA documents referenced above.

Is there an FAA or other standard which defines a comprehensive list of official criteria to qualify something as “Flight Hardware?”

My understanding is that it is a catch-all term for airworthy and tangible class III, II, or even class I product………as opposed to software, embedded or other.

Qualification requirements depend on the class and type of product as well as the application. Have you reviewed Part 21? If you are talking TSOA or PMA, you will ultimately be led to a set of RTCA DO-160 testing requirements for the particular item. Of course, I am only speaking from my own perspective.

In general, most and / or all customers have their own definition in their internal specs, generally driven by purchase order, purchase order attachments, contracts, and / or drawings. I do not know the proper protocol for copying primes definitions, but Bell Helicopter-Textron's definition of flight safety hardware, flight critical, flight primary parts can be found by googling Bell Helicopter-Textron's site and entering the wording "flight safety hardware in the search window at the upper right hand of the front page. HTH
TIA/R: Gary Wells

The term “Flight Hardware” is commonly used. When asked what constitutes “Flight Hardware” most people rattle off a similar list of requirements for objective evidence of tractability and surface coatings but where do these requirements come from.


Our commonly understood yet unofficial list of criteria for qualifying “Flight Hardware”:

Certificates of Conformance
Chemical Test Reports
Physical Test Reports
Manufacturers Lot Numbers
Passivation
Alodine or Anodize
Primer
Is there an FAA or other standard which defines a comprehensive list of official criteria to qualify something as “Flight Hardware?”

Here's a start:
Checked out DO-254, Design Assurance Guidance for Airborne Electronic Hardware it's used by the aerospace industry and has been around since 2005. Here's a wikipedia link to an explanation http://en.wikipedia.org/wiki/DO-254.

As far as requirements I've seen it vary from OEM to OEM based on the project you're working with. I personally don't have any knowledge of an exisiting procedure/specificaiton that calls this out other than TSOs.

Best regards,

al40

Flight hardware can also be stuff taken onboard that might be used during a flight like O2 bottles, the in-flight toilet, equipment for experiments, ....all sorts of stuff.

Somehow my question does not seem to be coming across. I have a piece of hardware that we wan to qualify for flight.

What requirements does it need to meet?

Is there an industry recognized process or standard for qualifying an item as “Flight hardware?”

In the process of qualifying a piece of hardware for flight what should I be verifying to then say it is qualified?

Somehow my question does not seem to be coming across. I have a piece of hardware that we wan to qualify for flight.

What requirements does it need to meet?

Is there an industry recognized process or standard for qualifying an item as “Flight hardware?”

In the process of qualifying a piece of hardware for flight what should I be verifying to then say it is qualified?

Are you looking to get FAA-PMA approval for flight hardware? If this is so, you will need a DAR (Designated Airworthiness Representative) to validate/verify the design/manufacturing data, a DER (Designated Engineering Representative) to verify the actual design, and all of the other items you mention.

Somehow my question does not seem to be coming across. I have a piece of hardware that we wan to qualify for flight.

What requirements does it need to meet?

Is there an industry recognized process or standard for qualifying an item as “Flight hardware?”

In the process of qualifying a piece of hardware for flight what should I be verifying to then say it is qualified?

What class of product are you talking about (class 1, 2, or 3)?

What is the product?

Is it truly just a piece of hardware or does it include embedded software? This is important since the inclusion of software greatly complicates the process.

What type of an approval are you seeking (TSO, PMA, STC, etc.)?

What type of aircraft are you hoping to install this hardware on?

As I said above, the requirements that you need to meet are totally dependent on the product as well as the type and scope of approval that you are seeking.

Again, have you reviewed Part 21? (http://www.airweb.faa.gov/regulatory_and_guidance_library/rgFAR.nsf/MainFrame?OpenFrameSet)

Our hardware is a small electromechanical pressure system to be installed on an experimental aircraft. It has no software.

I do not know what TSO, PMA, STC or class 1, 2, or 3 are. Can you enlighten me?

I have scanned through FAR Part 21 but it is a lot to read and I haven’t found anything applicable yet. Can you direct me to a specific section?

We are not seeking FAA approval. We only have to meet our own requirements but we do not have a standard set of requirements to meet so I am trying to find a precedent to base a set of requirements on.

Can anyone offer some specific examples of requirements to impose?

What distinguishes a piece of hardware which is qualified to fly from one which is not qualified?

I do not know what TSO, PMA, STC or class 1, 2, or 3 are. Can you enlighten me?

1. TSO= Technical Service Order

2. PMA= Parts Manufacturing Approval

3. STC= Supplemental Type Certificate

The TSO is normally used to correct something that may have been technically wrong with the Part, or to replace the part.

The PMA, is the FAA's authorization to sell and install the part and that it meets the original TC (Type Certificate) from the OEM (8130 Tag authorization to install)

The STC, is a changed or modified part that replaces the original PMA part or some difference in the design, but still meets the Type Certificate.

I think I have defined the use correctly, but I have been out of this type of Manufacturing for awhile.


Our hardware is a small electromechanical pressure system to be installed on an experimental aircraft.

Is this aircraft going to be submitted for authorization to fly after the experimental stage (get a TC)? If so, it now falls FAA control, unless it is used for Military application.

TSO = Technical Standard Order, a product certification

PMA = Parts Manufacturer Approval

TC = Type Certificate, think of it as a BOM for an aircraft

STC = Supplemental Type Certificate, think of it as a revised BOM to allow the installation of your product which was not part of the original TC

Class 1 = Aircraft, Aircraft Engines, or Propellers

Class 2 = a major component of an aircraft, aircraft engine, or propeller, the failure of which would jeopardize the safety of the aircraft, engine, or propeller.

Class 3 = anything that is not a class II part or a complete aircraft, engine, or propeller.

There is much language in part 21 regarding experimental classifications. With a little searching and reading, you should find some helpful information.

A certified piece of class 2 hardware may carry a TSO or PMA certification which indicates that it conforms to approved design data and in the case of TSO, FAA approved requirements for the product type. You can search for and read an example of a TSO for a product and it will ultimately lead you to a set of environmental testing requirements for the product via RTCA DO-160.

It is a very complex process and unfortunately, there is no easy answer or way around doing some extensive reading/research.

TSO = Technical Standard Order, a product certification

PMA = Parts Manufacturer Approval

TC = Type Certificate, think of it as a BOM for an aircraft

STC = Supplemental Type Certificate, think of it as a revised BOM to allow the installation of your product which was not part of the original TC

Class 1 = Aircraft, Aircraft Engines, or Propellers

Class 2 = a major component of an aircraft, aircraft engine, or propeller, the failure of which would jeopardize the safety of the aircraft, engine, or propeller.

Class 3 = anything that is not a class II part or a complete aircraft, engine, or propeller.

There is much language in part 21 regarding experimental classifications. With a little searching and reading, you should find some helpful information.

A certified piece of class 2 hardware may carry a TSO or PMA certification which indicates that it conforms to approved design data and in the case of TSO, FAA approved requirements for the product type. You can search for and read an example of a TSO for a product and it will ultimately lead you to a set of environmental testing requirements for the product via RTCA DO-160.

It is a very complex process and unfortunately, there is no easy answer or way around doing some extensive reading/research.

Well, I was close. Thanks for the more accurate info.

We are doing the initial qualification for a system we designed and manufactured. Therefore, TSO, PMA, STC are not applicable but their specific requirements may be helpful. Where can I find the specific requirements for these approvals?

Based on the provided definitions of Classification I would categorize it as Class 2; failure could jeopardize the safety of the aircraft.

The aircraft is will not fall under FAA controls. We do not have a policy for defining these requirements. The program is looking to me as the assigned Quality Assurance Specialist (self taught) to provide this direction. I would like to base it on an industry best practice but I can not find anything with specific requirements like my initial list.

I have already validated that the hardware conforms to the design but the design requirements are only based on our standard practices not an official policy or industry standard. Our acceptance test procedures are based on RTCA/DO-160D.

I will dig through FAR Part 21 more. It looks like Part 25 may be helpful too.

Thank you all for your time and effort.

I will dig through FAR Part 21 more. It looks like Part 25 may be helpful too.

Thank you all for your time and effort.

I hope I am not giving slightly inaccurate information, since I said I haven't been in the FAA realm for awhile.

I believe Part 21 is more directed to the Quality System, and Part 25 is more directed to the manufacturing side. You may also want to look at Part 145, even though at this point in time Repair would not be affected.

Where can I find the specific requirements for these approvals?

http://www.airweb.faa.gov/Regulatory_and_Guidance_Library/rgTSO.nsf/MainFrame?OpenFrameSet

I believe Part 21 is more directed to the Quality System, and Part 25 is more directed to the manufacturing side. You may also want to look at Part 145, even though at this point in time Repair would not be affected.

Part 21 - CERTIFICATION PROCEDURES FOR PRODUCTS AND PARTS

Part 25 - AIRWORTHINESS STANDARDS: TRANSPORT CATEGORY AIRPLANES

Part 145 - REPAIR STATIONS

The TSO is normally used to correct something that may have been technically wrong with the Part, or to replace the part.


Where did you get that definition from? TSO= Technical Standard Order. The operative word is standard. It is a minimum performance standard that must be met in order to be approved.

Where did you get that definition from? TSO= Technical Standard Order. The operative word is standard. It is a minimum performance standard that must be met in order to be approved.

Thanks for pointing that out. I think I already stated that the information was incorrect here:

Well, I was close. Thanks for the more accurate info.

and here

I hope I am not giving slightly inaccurate information, since I said I haven't been in the FAA realm for awhile. ...

Hi NQA Spec

The first thing I would do is get in touch with the FAA. They may refer you directly to the Experimental Aircraft Association (EAA) and / or help you directly. The equipment you have (I assume) designed and manufactured and wish to install in an experimental aircraft may need to undergo FAA approval under Part 21. This is because the experimental aircraft type you are planning to install it in carries an approval under an existing configuration. You are looking to change that configuration with your new system so may need to have the FAA approve the design change depending on the extent of the change. The kit manufacturer may be able to help here but the FAA will certainly confirm, it depends on the system you have changed and the risk this presents.

The FAA web site has a couple of AC's (Advisory Circulars) that you may find useful. It certainly makes references to the parts of Part 21 you may need to comply with. AC 20-27F describes the Certification of an Experimental Aircraft (of which you equipment will be installed) and AC 20-139 describes the commercial assistance the builder can utilise in the building of the EA. There's some other ones as well about certification of the builder and testing you need to undertake.

FDO is the best place to start for all of the above.

EAA web site is www.eaa.org FAA web site is www.faa.gov

Best of luck.

The aircraft is will not fall under FAA controls.
Is it military?

Is it military?

I do not know what the boundaries of disclosure are for this program.:cool:

I am just looking for any and all requirements which might be used to qualify something as “flight hardware” to consider in defining the criteria we will impose.

I do not know what the boundaries of disclosure are for this program.:cool:

I am just looking for any and all requirements which might be used to qualify something as “flight hardware” to consider in defining the criteria we will impose.The aircraft manufacturer will define the requirements. Then you will meet them and supply the "part" to be installed on the aircraft. The aircraft mfr will get a production approval for the "type" aircraft that your part is installed on. At that point you still can't sell your part directly to the operator, only to the approval holder. This would need to be done for each "type" aircraft. In order to sell directly, you will need a Parts Manufacturer Approval (PMA) for each aircraft the part is installed on. The process to apply for PMA is described in FAA Order 8110.4b. FAA Orders are instructions for the FAA to use. You can post additional specific questions in this thread. BTW, I was an FAA Designee for around 7 or 8 years. Although I haven't done it in a while and some of the details may have changed, I think I can still navigate the regulations and associated documents.

It could be a UAV Al ???

It could be a UAV Al ???Could be anything, but basically the aircraft manufacturer determines the requirements.