Air Cargo System
project name

Air Cargo System

Improving Carrying Capacity


Leveraging an international team approach to meet compressed timelines.


CaseStudy5Problem Statement
A modern turboprop transport aircraft required a major effort to increase the load carrying capability of the pallet system. The aircraft manufacturer and cargo handling system provider reached agreement during the development of the aircraft to increase the load holding capacity of the system by approximately 200% with limited overall weight impact.

With very little time remaining to aircraft certification, Ingenium Aerospace was contacted by the cargo handling systems provider to arrange for a team to assess the current design and work cooperatively with the aircraft manufacturer and cargo handling systems provider to create the improved design with the capability to meet the increased load capability, durability, and reliability demands for the vehicle.

The effort encompassed redesign of many of the load bearing members of the cargo handling system and required active coordination, cooperation and transparency across a multi-national team. Ingenium provided a team of forty highly-skilled, experienced design associates, some of whom were deployed and led a team in Bremen, Germany while others resided at Ingenium’s facility in the United States along with staff from the aircraft manufacturer and cargo system provider.

Both teams were led by an Ingenium Program Manager, who created and managed document configuration control through a remotely linked network which connected back through the Ingenium’s secure computer servers and design vault. As the Bremen, Germany team finished their daily efforts, a continuation of the day’s work was beginning in the US office, taking full advantage of the time difference to further progress the designs and compress the schedule. This approach allowed work to evolve for 20 hours within a 24-hour period.

Results & Outcome
The increase in the cargo handling system carrying capacity was achieved within four months. The cooperation and focus of the teams, coupled with the strategies to achieve the compressed schedules proved successful and the design was ultimately certified, fielded and is currently flying successfully in production.