Aerospace

At Calcate, our engineers have extensive experience working in the aerospace industry, working for the Original Equipment Manufacturers (OEM) and large/small Tier 2 suppliers. We have experience working on fuselage, landing gear, seats and interiors, engines, control surfaces and more.
We have experience building models from scratch, and doing sophisticated analysis such as bird strike, engine blade-off, fuselage crash, seating dynamics, aircraft water ditching, etc.
When it comes to analysis in aerospace, we can assist you from initial design to certification.

Airframes

At Calcate, our engineers have worked on numerous small aircraft, electric vertical take off (Evtol) planes and drone programs from inception to first flight. We have sized and analysed components, assemblies and full aircrafts using a building block approach. Confidence is built in the modelling and materials by first performing coupon level analysis and testing, followed by element level, subcomponent and then full aircraft level analysis, testing and correlation.
We have sized by performing extensive detailed analysis on metallic and composite airframe structures to meet industry requirements for strength, fatigue and crash load cases. Our specialized knowledge and experience in analysing and test correlation includes:
Fuselage drop testing, fuselage bird strike , aircraft ditching, landing gear, battery protection, aircraft seats and occupant safety.

Landing Gear

The landing gear is a vital aircraft subsystem, providing suspension during taxi, take-off, and landing. It must be designed to absorb and dissipate kinetic energy, minimizing impact loads on the airframe and preventing fuselage contact with the ground. Landing gears aim for lightweight, compact size, high performance, extended fatigue life, and improved cost efficiency, while adhering to regulatory and safety standards.

At Calcate, our engineers have extensive experience sizing and analyzing landing gears for aircraft of various sizes. We utilize beam models to derive loads and employ a combination of classical hand calculations and FEA to perform static (limit & ultimate) and fatigue analysis on all main and nose gear components.

Aircraft Seats & Interior

Our engineers have over a decade of design, analysis and testing of economy, premium economy, business and first class aircraft seats. We have the expertise to design seats by a mixture of analysis and testing often creating FEA models from scratch. We have sized seats with static loads, tested them quasi-statically, before performing dynamic analysis (forward, down & HIC with Hybrid III dummy) followed by dynamic development tests for modelling correlations, and finally Certification tests. We also perform optimization to reduce weight and increase performance while maintaining strength and stiffness to meet requirements.  Our design, analysis and testing experience reduces the aircraft seat design and development cycle time while meeting the safety and regulatory requirements..

Drones

At Calcate, we have worked on a wide range of drone project ranging from miniature to heavy lift drones from inception, first flight to autonomous missions. We can assist you in converting your core needs to a set of requirements that can be met with the right drone. Our analysis and testing expertise combined with our partners’ drone architecture, avionics and manufacturing experience allows us to achieve a high capability drone that is durable, rigid, light weight and houses the systems needed to meet your requirements. From quad-copter, fixed wing to fixed wing VTOL, we have you covered.

Automotive

At Calcate, our engineers have experience in the conceptual design and analysis of road vehicles, kit cars, custom and off road vehicles. We perform common initial vehicle analysis such as chassis bending, torsional stiffness, dynamic analysis, side and front impact. Subsequent CAE analysis is done on body, chassis and interiors with sub model and/or full vehicle models being built from scratch or modifying past models.
Our engineers are also experienced in the analysis and testing of special off-road vehicles, performing load cases such as crash, sand dune impact, vehicle rollover, recovery, tie-downs and heli-lift. We also assess various add-on assemblies including cranes, winches and other modifications that require detailed analysis.

Defence

To create a safe and secure world, Calcate provides engineering services to improve the capability and reliability of our customers’ assets cost effectively. We have assisted our clients to design, test, modify and maintain ground vehicles, drones, surveillance and personal protection products. When safety is critical, we can help.

Consumer Products

Our design and analysis experience allows consumer goods manufacturers to increase innovation, reduce product development time and minimize costs while achieving performance and warranty targets. We analyse for strength, aging/cycle testing, thermal, drop and impact loading to solve design challenges first time, while reducing costly and time consuming prototype builds and physical testing.
Typical consumer products include food and beverage, packaging, home and kitchen appliances, furnishings, sports equipment and leisure goods.
Our engineers optimise the design early in the design cycle which produces high quality products with a shorter time to market while meeting regulatory standards and avoiding warranty problems down the line.

Industrial Machinery

At Calcate, we have experience working with industrial tools and equipment manufacturers to design products that are fit for purpose to handle extreme load cases and harsh conditions. Our analysis enables the design of complex industrial equipment quickly, while verifying strength, durability and performance to avoid premature failure, reduce machine downtown and increase safety.
Typical industrial equipment include equipment for lifting, moving, material handling, storage, farming, construction, mining, manufacturing and workshop. By performing analysis such as stress, deflections, fatigue, vibration, impact and thermal, our customers can design machines and tools with high performance, shorter time-to-market while meeting regulatory and safety standards.

Energy

Our engineers have industry experience working on devices, structures and systems used in the clean and renewable energy. We have helped clients size, analyse and test components using static, vibration and dynamic load cases. Typical energy components include aircraft battery systems, electric vehicle charging equipment, renewable energy structures, hydro energy components, wind and offshore energy devices.

Bespoke

At Calcate our engineers have the experience needed to help you design and analyse bespoke products from concept through to detailed manufacturing drawings. We help our clients design products small enough to fit your pocket to large industrial machinery, often gathering the required data on their behalf before using it to meet their strength, reliability, performance and safety requirements.
We perform an simple hand calculations initially, followed by the required detailed analysis such as stress, displacements, fatigue, vibration, thermal, impact and crash analysis to ensure the design meets requirements.
Our clients range from start-ups with a single product to large companies that need to reduce product development time and meet tight deadlines by getting it right the first time with analysis. We are here for you every step of the way.