Save Time. Optimize Faster. Automate Engineering and Business Workflows.

We help aerospace and engineering companies automate repetitive technical and administrative tasks — from simulation setup to internal reporting — saving hundreds of hours and unlocking faster, smarter decisions. Specialized in multidisciplinary optimization (OpenMDAO) and custom process automation.

Risk-Free Commitment: No payment is required until results are delivered and you’re satisfied.

Proven Time Savings: Reduce production/manufacturing/simulation or design cycles by up to 45% with custom automation.

Deep Technical Expertise: We work with industry-standard tools like OpenMDAO,SAP,ANSYS, MATLAB,Excel VBA,etc..

Data-Driven Results: Every project includes quantifiable KPIs — you’ll see exactly what we improve.

Tailored Engineering Automation: We design solutions that fit your team’s workflow and remove the repetitive work.

Fast Turnaround: From prototype to deployment in days, not months.

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Services

At Airborne Consulting Services, we eliminate repetitive work across engineering and business teams.

We specialize in workflow automation, simulation acceleration, and multidisciplinary design optimization (MDO) using NASA’s OpenMDAO framework — but we don’t stop there.

From automating simulation chains to cleaning up complex Excel data, we save you hundreds of hours and help your teams focus on high-value work.

Engineering Process Automation

Automate simulation setup, data flow between CFD/FEA tools, multi-physics optimization.

Business Workflow Automation

Automate Excel processes, internal reporting, compliance checklists, approval flows.

Multidisciplinary Design Optimization (MDO)

Connect aerodynamics, structures, propulsion, and cost models to find the best designs automatically.

Simulation Workflow Acceleration

Build pipelines that reduce manual simulation time by 50–80%.

Data Management and Auto-Reporting

Automate data collection, clean-up, and professional report generation.

Some of our projects

Designing cutting-edge jet engines and propulsion systems that adapt to both subsonic and supersonic regimes, with a focus on efficiency, thermal management, and performance. From variable cycle engines to modular spacecraft propulsion, these projects showcase mastery in next-generation aerospace engineering.

Hybrid-Electric Aircraft Propulsion Optimization

Sector: Aircraft Design & Optimization

  • Challenge:
    Traditional propulsion optimization processes took 4–6 weeks per design iteration, creating bottlenecks during preliminary design stages, delaying product development, and raising costs.
  • Solution:
    Developed an automated Multidisciplinary Design Optimization (MDO) workflow using OpenMDAO, integrated with MATLAB/Simulink and SolidWorks. The new approach allows simultaneous optimization of battery capacity, propeller sizing (BEMT), and overall aircraft energy consumption.
  • Impact:
  • Reduced itereation time by 85% (4 weeks → 3 days)
  • Aircraft energy consumption optimized by 15%, increasing effective range

Automated Generation of Engine Performance Maps

Sector: Propulsion & Performance Engineering

  • Challenge:
    Generating detailed turboprop and turboshaft engine performance maps for new engine variants typically required manual interpolation and took engineers up to 2 weeks per map
  • Solution:
    Implemented automation scripts using MATLAB and Python that rapidly interpolate test data and simulations to generate complete engine maps (TSFC, Torque, Power vs. Altitude & Speed) in minutes.
  • Impact:
  • Map creation reduced by 95% (2 weeks → 1 hour)
  • Enabled rapid evaluation of multiple engine variants
  • Improved accuracy and eliminated manual errors

Structural Load Case Analysis Automation

Sector: Structural Analysis & Certification

  • Challenge:
    Evaluating structural margins across hundreds of load cases (gust, landing, maneuver) in aircraft wing and pylon structures consumed approximately 3–4 weeks per analysis cycle, delaying certification milestones.
  • Solution:
    Created a comprehensive automated Excel VBA-based tool integrated with ANSYS Mechanical results that instantly evaluates and visualizes margins of safety across load cases. A complementary Power BI dashboard summarizes structural status in real-time.
  • Impact:
  • Reduced structural evaluation time by 70% (4 weeks → 1 week)
  • Early detection of critical cases, reducing certification risk by 40%

Engineering Change Request (ECR) Automation Tool

Sector: Aerospace Project & Business Management

  • Challenge:
    Managing Engineering Change Requests (ECRs) manually led to communication delays, missed deadlines, and productivity losses of approximately 20 engineering hours per week.
  • Solution:
    Designed and deployed a fully automated Excel VBA-based ECR tracking system. Automatically assigns, escalates overdue tasks via Outlook email alerts, and generates weekly management summary reports.
  • Impact:
  • Reduced administrative workload by 80% (20 hours/week → 4 hours/week)
  • Increased on-time ECR completion by 25%

Icing Envelope Automation Tool

Sector: Flight Safety & Operations

  • Challenge:
    Traditional icing risk assessments for UAV and regional aircraft in Canadian winter conditions required manual analysis, taking approximately 8 hours per mission, leading to delays and occasional unsafe dispatches.
  • Solution:
    Developed an automated icing envelope estimator using Python, MATLAB, and integrated atmospheric models. Provides rapid real-time visualization of icing risk zones for flight paths and altitudes.
  • Impact:
  • Reduced icing risk assessment time by 90% (8 hours → 45 minutes)
  • Decreased mission cancellation rate due to uncertainty by 30%
  • Enhanced operational safety and compliance with Transport Canada guidelines

CFD Simulation Workflow Automation for Rotorcraft Aerodynamics

Sector: Computational Fluid Dynamics & Aerodynamics

  • Challenge:
    Aerodynamic CFD simulations for rotorcraft blades traditionally involved manual setup and required 2–3 weeks per iteration, delaying critical aerodynamic evaluations and blade design updates.
  • Solution:
    Implemented an automation workflow using ANSYS Fluent, CATIA V5, and Python scripting to automatically set up, run, and post-process aerodynamic simulations, significantly accelerating the CFD workflow.
  • Impact:
  • Reduced CFD analysis cycles by 85% (3 weeks → 3 days)
  • Increased aerodynamic efficiency predictions accuracy by 20%
  • Enabled rapid design iterations, shortening product development timelines by months

Automated CAD-to-FEA Pipeline for Landing Gear Systems

Sector: Mechanical Design & Structural Integrity

  • Challenge:
    FEA analysis of landing gear assemblies involved repetitive manual steps in geometry transfer, mesh setup, and loading definition, taking up to 3 weeks per analysis cycle.
  • Solution:
    Built a fully automated CAD-to-FEA analysis pipeline connecting SolidWorks directly with ANSYS Mechanical, driven by Python automation scripts. Enables quick and accurate structural integrity assessments.
  • Impact:
  • Decreased analysis cycle times by 80% (3 weeks → 4 days)
  • Improved accuracy of fatigue and stress predictions by 25%

“Before Airborne Consulting stepped in, our design cycle time was killing our program. Their automation tools cut our analysis time by 70% and gave our team the breathing room to focus on actual engineering.”

Specializing in aerospace consulting, we provide expert solutions for companies and individuals seeking guidance in aerodynamics, systems engineering, and cutting-edge aerospace technologies. Our goal is to support your projects with tailored advice, industry insights, and innovative strategies to ensure success in a rapidly evolving sector.

Contact us

info@airborneconsultingservices.com

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