Bespoke sensors - Replicating Aircraft Components

Reproducing in-flight loads on a real aircraft specimen sometimes means measuring forces from inside the component itself, and when space is too tight for an external sensor, the answer is replacing the actual part with a purpose-built one that measures as it works. Interface's approach starts with 3D CAD modelling once a customer releases details of the area around the fixing point and the working conditions involved, then moves into designing a bespoke sensor and negotiating any local structural modifications needed for cable exit or anti-rotation stops. One project of this kind involved replacing standard hinge bolts in an otherwise standard assembly, deciding whether a down-hole gauging design was appropriate, and taking special care over gauge position given the unsupported region involved, right down to manufacturing custom calibration loading fittings, since a load pin's accuracy depends heavily on the quality of the fittings used to calibrate it.