Our approach to product design and development is entirely focused on creating innovative solutions for existing problems in the most practical and cost-effective manner.  Central to achieving this is having a full understanding of the problem that we are trying to solve and that requires us to have close working relationships with our clients.

In all of our projects, we actively seek input from industry and we continue to engage with our clients throughout the entire design and development process.  Although it may sound cliched, we genuinely believe that our best designs and best products are those that we have developed in partnership with our clients and industry partners and we like to think that this approach sets us apart from other companies.

If you have a project that you’d like to discuss with our team, we welcome the opportunity to work with you.  Please contact our team who will be happy to provide you with a proposal at no cost and no obligation to you. 

Further information on the services that we offer is provided below.

Research & Development

Our team have a proud history of collaborating with tertiary institutions, test laboratories and industry partners to research ideas and develop novel solutions to complex problems. 

Examples of some of the research projects that we are currently undertaking include:  

  • Air Mobile Stroke Unit – Our team is working closely with the Australian Stroke Alliance (ASA) and RMIT University to develop the world’s first air mobile stroke unit capability.  
  • Transportable Bio-Containment Hood – Five Rings is assisting in adaption and trials of the ventilation hood technology developed by The University of Melbourne and Western Health, for ambulatory and patient transport use.
  • SkyBudi Hybrid Stretcher – Five Rings has partnered with the team at MedicalConnect and Swinburne University to assist with developing their SkyBudi hybrid stretcher concept.  The Skybudi is designed to assist people with medical and mobility limitations to be transported safely and comfortably on a commercial flight.  

Design & Analysis

Product design is an iterative process where design and analysis often go hand-in-hand.  Once the basic design has been agreed with our client, we commence the detailed design and analysis phase which involves preparation of manufacturing data packages and analysis reports and certification plans. Examples of the design and analysis capabilities that we offer include:


Conceptual Design:

  • Aircraft configuration and layout design
  • Weight and Balance modelling
  • Concept drawings and preliminary 3D rendering
  • Preliminary review of certification/design constraints

Detailed Design:

  • Full detail 3D CAD modelling
  • Develop manufacturing drawings
  • Development of process specifications
  • Design tooling and fixtures
  • Industrial design – materials, finishes, function


  • Structural analysis
  • Finite Element Modelling and analysis (FEM/FEA)
  • Fatigue and crack growth analysis
  • Aircraft performance analysis
  • Stability and control analysis
  • Systems Safety Analysis (SSA)
  • Weight and Balance analysis


We offer an extensive range of ground and flight testing services. Some examples of the testing services that we provide are listed below:

Ground Testing

The ground testing services that we offer include both in-house testing and external laboratory testing at one of our partner facilities:

  • Static rig testing
  • Dynamic testing (aircraft seats)
  • Vibration testing
  • Water tank testing
  • Wind tunnel testing
  • Flammability testing
  • EMI/EMC testing 

Flight Testing

Five Rings Aerospace is a highly regarded and experienced fight test organization with extensive experience in developmental and certification flight testing. Our capability spans both fixed and rotary wing aircraft with years of experience in testing and certifying aircraft and helicopters both within Australia and overseas.

Our Flight Test Pilot

Our test pilot is an experienced former military test pilot with extensive rotary and fixed wing experience. Following a 21 year military career he has worked in civil flight test for the last 12 years in developmental and certification flight test on numerous projects within Australia and New Zealand ranging from full aircraft certification projects such as the GippsAero GA10 through to Cargo Pod installations on AS350 in New Zealand. He holds a CASA flight analyst delegation and CAA NZ flight analyst and test pilot delegations.

Developmental Test Flying

We have extensive experience in developmental test flying helping clients explore innovative solutions to problems.

Certification Test Flying

Our flight test pilot and engineers have broad experience certifying everything from the simplest modification through to whole aircraft certification programs. Five Rings Aerospace holds Flight analyst and flight test pilot delegations for fixed and rotary wing aircraft within Australia (CASA) and New Zealand (CAA NZ).

Flight Test Training

Five Rings Aerospace offers comprehensive hands on training in flight test planning and conduct. Training has been conducted in New Zealand providing post graduate level instruction to engineers from within the NZ aerospace industry and to CAA NZ staff.

Prototype & Production

Our production facility is based in Tullamarine, Victoria and includes a team of aircraft maintenance engineers, product design engineers and quality management.

To assist with conceptual design and development, our production team provide rapid-prototyping services utilising 3D CAD modelling and 3D printing to quickly produce prototype parts for trial installation and functional testing.  3D printing significantly reduces the design development time and our team is able to offer 24 hour turnaround time for modelling and 3D printing of prototype parts.

For part production, our workshop is a CASA (Australia) certified Production Organisation which authorises us to manufacture and release aircraft parts with a Form 1 Authorised Release Certificate.  All parts that we manufacture are controlled by a CASA approved Manufacturing Quality System ensuring that they are manufactured to stringent aviation quality standards.

Our manufacturing capability includes:

  • 3D laser scanning
  • 3D printing
  • Sheetmetal fabrication
  • Machining
  • Wire harness fabrication
  • Composite fabrication
  • Aircraft Welding
  • Component repair and overhaul
  • Conformity inspection


One of our core business strengths is our ability to certify the designs and products that we produce.  We don’t rely on external design organisations to certify our designs and this enables us to provide efficient product delivery without the uncertainty of costly certification delays at the end of a project.

Five Rings Aerospace is an authorised Aircraft Design Organisation recognised by the following regulatory authorities:

  • CASA (Australia) Part 21
  • CAA NZ Part 146 Design Organisation
  • CASA (Papua New Guinea) Part 146 Aircraft Design Organisation

We also regularly work with partner organisations in the FAA and EASA systems to provide foreign certification where required.

Our scope of approval for in-house certification includes:

  • Aircraft Structures
  • Mechanical Systems and Equipment
  • Electrical Systems and Equipment
  • Avionics
  • Flight Test

Weight & Balance

Five Rings Aerospace has a team of authorised Weight Control Authorities with authorisation to weigh and develop loading systems for rotary and fixed-wing aircraft.

We utilise both jack-mounted compression load cell systems and floor-mounted platform weighing systems and provide on-site weighing services throughout Australia and Papua New Guinea.

Our team is also highly experienced at developing electronic loading systems customised to suit our clients unique mission requirements.

The weight and balance services that we provide include:

  • Aircraft weighing and weight validations
  • Electrical Loading Systems
  • Manual Loading Systems (Trimsheets)
  • Fleet Weighing Systems

Whether you're looking for advice on a one-off project or a complete design service, we're ready to help.

Get in touch to discuss your aircraft design and modification requirements.