component apart; to measure it, to conclude that PMA’d parts are as not
Some of Rapco’s PMA’d Parts determine its composition and design, as good as the OEM originals.
and generally whatever else is required “Ten years ago, PMA’d parts were
Vacuum pumps are not the only PMA’d part to reverse engineer it,” says White. generally seen as inferior to OEM parts;
where Rapco has improved upon the OEM “Only after we have a thorough unfairly, I might add,” White says. “But
original. Also sporting improvements are understanding of the component do times have changed since then: Thanks
brake linings, nickel disc brakes and propeller we try to improve it. Some of the ideas to the efforts of MARPA [the Modification
de-icing components. – such as inspection ports in vacuum and Replacement Parts Association],
Car owners are accustomed to wear pumps -- come from our own people; PMA’d parts are treated with far more
monitors on their brake pads, allowing them others are inspired by customers who respect. In fact, some airlines even have
to know when replacements are required. are looking for a PMA’d replacement.” PMA procurement departments! Still,
Rapco has brought the same advancement Some improvements are simply a factor the not-OEM stigma remains for some
to its aircraft brake pads. All it requires is a of experience: “When you PMA a part people. Even today, we have to deal with
small semi-circular indent in the side brake that was designed in the 1960s, naturally this misconception.”
lining, making visual inspection possible from the techniques and materials you have A second challenge for Rapco and
the side of the brake assembly. Rapco’s brake at hand are more advanced than what RFS is the economy. As air traffic
linings are made from a high temperature the OEMs had to work with,” he notes. dropped due to tight budgets, so too
Kevlar fiber composite to provide more Once the PMA’d part has been did demand for aircraft parts. “We sell
friction and longer pad life. machined and manufactured, “we put consumables,” says Keagle. “If aircraft
Rapco’s nickel brake discs are made from it through rigorous testing; both on are not flying as much, then the parts
forged steel, using a heated one-piece design the ground and in the air, which, in they have aren’t being worn out as
instead of casting or welding. According to the case of a brake part, consists of a quickly. Obviously, that affects our sales
the company, one-piece forged discs are four FAA mandated performance flight test volume and our bottom line.”
times stronger than welded discs. Meanwhile, including landings at various aircraft Finally, the third challenge is growth.
their nickel plating resists rusting and corrosion weights and max-weight rejected take- To keep expanding, “we have to keep
cracking. “RFS has responded to customers offs (RTOs),” Keagle says. “Only after developing new PMA’d parts, to grow
requests to increase cycle life, and have - by we are sure of the part, do we submit the size of our market and the range of
using our proprietary friction mix - seen up it to the FAA for approval. When that people who need our products,” White
to 40% longer cycle life,” says Keagle. “This process has been concluded, we can says. “This costs money to identify
reduction in per landing cost has been a start to produce for the aftermarket.” possible market niches, reverse engineer
welcome improvement for corporate and the parts, test them, and then earn FAA
commuter operators.” Challenges approval. That’s not easy to finance
Finally, Rapco’s de-icing components: According to Pat White, OEMs don’t like when you are dealing with recession-
The propellor de-ice brushes are made PMA’d parts. There’s good reason for affected sales.”
with an improved carbon compound to their hostility: PMA’d parts cut into OEM
extend operational life. The de-ice leads are sales. In particular, it can be argued that Looking Ahead
designed to be stronger and more flexible, PMA’d parts take advantage of the R&D Despite these challenges, Rapco and
and the plugs and terminals are crimped in money spent by OEMs in designing RFS seem poised for future success.
a manner that enhances their durability. “It’s new aircraft; an investment that can The reason is simple: People like
all about making things last longer and work only be recouped through high-profit PMA’d parts that do the job of OEM
better,” says Pat White. “Even something sales of replacement parts. Whether components, but cost less. “As long
small, like how we crimp our de-icing you subscribe to this argument or not, are there are aircraft, there will be a
terminals, can make a big difference for the fact is that OEMs do not go out of demand for PMA’d parts,” Pat White
aircraft operators.” their way to promote PMA’d parts. This says. “That’s why this company was
reality, plus their lower price and lack of founded 27 years ago, and why it has
Citations; plus parts for the Beech King OEM brand name, has led some people kept growing since then.”
AM
Airs and 1900s, among others.
Creating PMA’d Parts
The PMA process begins with an OEM-
exclusive component - something that
is in common use and requires repair/
replacement on an ongoing basis. This is
why brakes are such a natural for PMA’d
parts, because aircraft go through a
number of pads, disks and other parts
over time.
“We begin by taking the OEM
Rapco Regs and fittings Rapco Pumps
38 Aviation Maintenance |
avmain-mag.com | December 2009/January 2010
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