NOTE: THE DEVELOPMENT OF FOLLOWING SYSTEMS/ PRODUCTS COULD NOT BE FORMALLY DISCLOSED/ PATENTENED DUE TO COMPANY WIDE RESTRICTIONS;
- Affordable Manufacturing of all Composite Aerospace Structural Systems:
Executed design, development, testing and production of all composite airframe systems of long range, canard configuration, pusher type UAVs, high performance aerospace vehicle systems and other complex structural components such as wings, fuselage, nose cone, tail plane from carbon-epoxy composites using vacuum assisted technologies through NASA TRL. Optimal resource mobilization & tight process control reduced part rejection, enhanced production and saved multi millions US$ for company.
- All Composite Bodies of Automotive Vehicles:
Shell Eco and Formula-1 automobile car bodies were developed from carbon-epoxy composites skin and nomax/ foam sandwich floor using single step resin infusion process for GIK Institute of Science & Technology, NUST and NED University to take part in international races.
- Ballistic Body and Vehicle Protection:
Accelerated research about ballistic protection sponsored by DuPont as part of graduate and UG research at NUST College of E&ME led to development of 1st prototypes of bullet proof jacket and PASGAT helmet. Commercialized the project by producing 3,000 bullet proof jackets for Ministry of Interior, Gilgit Scoutes, Punjab Rangers, Pak Army, PAF and ballistic protection of high value 20 PAF vehicles.
- Development and Rehabilitation of Radoms:
New radoms of aerospace vehicles having electromagnetic loss (<1 Db) were developed from glass-epoxy composites. The nomax sandwich radoms of 6 Lockheed C-130 transport aircrafts were repaired using HSC9200B Heatcon Composite Repair System. This involved zoning, tabbing/ ultrasonic NDT, surface preparation, in situ curing, mechanical testing. Saved multi millions of US$ in FE.
- Helicopters Structural Overhaul/ Rebuilt and Evaluation:
Successfully overhauled, rebuilt and test flown first 2 Puma Helicopters according to 10 phase overhaul plan. This involved structural analysis, FEM, NDT, mechanical testing and replacement of its metallic with composite structures. Saved multi millions of US$ in FE.