As DAIR’s Manager of Workforce Development and Sustainability, Spyro Cacoutis will be integral in to the development and execution of customized training solutions for current and future DAIR partners. Spyro will also work to identify current industry needs and sector trends and help to define ways in which DAIR can leverage its juxtaposition between industry and academia to support the aerospace sector, and specifically SMEs.
Spyro has nearly 40 years’ experience in the aerospace industry and has worked on aerospace programs involving the de Havilland Dash 8, Boeing 787, Airbus A380 and Lockheed Martin F22. He has experience with Materials and Processes, Design Engineering, Lean Manufacturing, Quality Assurance, Airworthiness and Laboratory testing. Spyro was the lead auditor for Composites for PRI-Nadcap and a Transport Canada DAR for Interiors Flammability for the Dash 8 aircraft. He also taught a continuing education course on Advance Composites Technology at the University of Toronto Faculty for Applied Science and Engineering. He is a graduate of the University of Toronto with Bachelors and Masters degrees specializing in Aerospace Engineering.
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Project Title: Research & Design of an Optimized Rotor Alloy for Aircraft Eddy Current Brake Applications
Project Description: The technology behind Aeroflux's innovative contactless brakes is based on the principle of eddy current braking. Whereas a typical friction brake decelerates an aircraft through friction generated by bringing a moving and non-moving surface (the stator and the rotor) in contact with one another, an eddy current brake does so without the need for any physical contact between the stator and the rotor. Currently, there are alloys present to perform the work but with limited success on life and consistent performance. An optimization of a current alloy or development of a new alloy will be required to provide consistent performance metrics and meet target life expectations for commercial applications.
Environmental Impact: Frictionless eddy current brakes do not wear, and no brake replacements are required. Eddy brakes produce half the lifetime CO2 emissions of traditional friction brakes.
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Project Title: Development of Process to Phase-Out Hexavalent Chromium Compounds from Anodizing and Plating Processes
Project Description: Brampton Processing is developing a process to phase-out toxic Hexavalent Chromium Compounds from its anodizing and plating processes. The goal of the project is to eliminate toxic hexavalent chromium emissions into the environment and replace it with less toxic trivalent chromium emissions.
Environmental Impact: Reduced toxic emissions in anodizing and plating processes for metal finishing in aircraft manufacturing. This new process will reduce occupational health risks.
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(samuel.com/burloak-technologies)
Project Title: Development of Tungsten Additive Manufacturing & Heat Treatment Processes for Canadian Aerospace
Project Description: The development and use of tungsten powder is very nascent for laser powder bed fusion additive manufacturing (AM) technology. With recent demand for AM tungsten development within the aerospace/defence industry in Canada for purpose-driven weight balancing parts for helicopters, as well as radiation shielding for electronic components, this project will serve to create an all-Canadian solution to meet this demand. It will develop AM processes at Burloak necessary for the use of tungsten, and the tungsten powder will be sourced locally through Tekna in Canada, which is beneficial for security purposes, as other major suppliers of tungsten come from Russia and China.
Environmental Impact: Compared to convential manufacturing methods, additive manufacturing provides a reduction in material waste, energy usage and machine emissions.
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Project Title: Care by Air – Transport of Time Critical Medical Supplies by Remotely Piloted Aircraft (Drone)
Project Description: The project is a collaboration between Drone Delivery Canada, DSV Air & Sea Inc – Toronto, McMaster University and Halton Healthcare Services Corporation. Through a pilot project, the partners will explore the viability of using remotely piloted aircraft (drones) for the delivery of isotopes and other vital medical supplies from point of production to patients in hospitals, with the aim of alleviating supply chain uncertainties in the transportation of these medical products.
Environmental Impact: Reduced CO2 emissions from less reliance on traditional aircraft for delivery.
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Project Title: HEBÉ Hydrogen Storage and Management for Use as Aircraft Fuel
Project Description: HEBÉ Hydrogen is developing techniques for sealing of underground cavities so that green electrolytic hydrogen produced at pressures of up to 35 bar(g) can be safely stored for future processing. A key challenge is to find an affordable way to install underground storage in the most difficult geologies on earth. HEBÉ has partnered with Petra, as the leading trenchless boring expert, to reduce the cost of undergrounding and to make it economically viable. As part of the project, HEBÉ will use Petra’s knowledge in scaled-up cost and technical models. It is anticipated that engineering and field validation works will generate intellectual property registration opportunities for HEBÉ Hydrogen. The project would demonstrate up to two methodologies in this proof-of-concept effort.
Environmental Impact: The hydrogen-storage repositories will provide 100% availability of green fuel on-site for air transportation in all remote regions.
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Project Title: Engineering Design of a Hybrid Power System Novel Power Distribution Scheme
Project Description: Horizon Aircraft is developing a unique hybrid electric Vertical Takeoff and Landing (VTOL) aircraft. To take off and land vertically, the aircraft uses an array of electrically driven lifting fans located in both the main wings and the canards that draw significant power during this short phase of flight. As such, it is beneficial to have a power distribution schema wherein electrical power for vertical flight is routed from two distinct sources: (1) directly from the generator that is part of the main hybrid electric power system; and (2) from an on-board battery array.
Environmental Impact: Use of electrical and battery power in hybrid systems will reduce requirements to use emission-causing fuels.
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Project Title: Development of Lithium-ion Battery for Small Drone and UAV applications
Project Description: This project is to develop a 5 Ah lithium-ion battery for testing in a small unmanned fixed-wing drone application. Solid Ultrabattery anticipates that high energy-density lithium ion or lithium metal batteries more than 400Wh/kg will be required for aerospace and drone applications, due to high energy demands during takeoff and cruising stages of flight under inclement weather conditions. The initial battery will target 400Wh/kg as a starting point. The goal is to develop a small 5 Ah building block for a much larger battery that can be developed in the future for substantially larger flight vehicles.
Environmental Impact: Use of lithium batteries will reduce environmental emissions compared to use of traditional fuel sources.
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(ova.ai)
Project Title: PhygitalX - Remote Training, Unrestricted
Project Description: PhygitalX is a software used on the latest extended-reality hardware, combining the best of virtual reality (VR) and augmented reality (AR) to remove the requirement for physical travel in training sessions for aerospace manufacturing or maintenance, while preserving the integrity of the learning experience (a feat otherwise impossible with VR-only or AR-only software). Remote training activities are no longer compromised or restricted – everyone, regardless of physical location, has holistic engagement and presence. Cost savings are significant when remote training sessions are just as good or better than in-person sessions.
Environmental Impact: Reduction of environmental emissions by making high-quality training possible without the need for travel.
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A. Berger Precision Ltd.
High precision machining and manufacturing of components and highly complex assemblies.
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AirStart Inc.
Supplier of OEM and aftermarket airplane parts and components to the global aviation and aerospace industry.
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Aerospace Metal Finishing Inc. (AMF)
Surface finisher specializing in coating, passivation, anodizing etc. of fabricated metal parts.
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Aversan Electronics Manufacturing Inc. (Aversan EMI)
Manufacturer specializing in high complexity electronics assemblies.
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Avion Technologies Inc.
Manufactures gears, precision components, and sub-assemblies for the aviation and space industry.
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BMP Metals (A division of Bempro Global Group Inc.)
Specialized in fabricated metal products with capabilities in punching, forming, welding, wet and powder coatings, milling and turning, electrical assembly, 3D plastic printing and mechanical assemblies.
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Brotech Precision CNC Inc.
High precision metal components manufacturer for the aerospace industry.
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CFN Precision Ltd.
Supplier of complex, precision-machined components, kits, sub-assemblies and testing for the aerospace industry.
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Cleeve Technology Inc.
Specializes in the supply, design, and manufacturing of electrical interconnect products, including but not limited to, wire harnesses, cable assemblies, boxes, panels and enclosures.
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Coordinate Industries Ltd.
Manufacturer of cable assemblies, wire harnesses, mechanical and electromechanical assemblies.
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Dellcom Aerospace
CNC milling and turning capabilities for small- to medium-size parts for the aerospace industry.
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Devtek Aerospace (Centre of Excellence)
Machining of medium- to large-size landing gear components.
www.herouxdevtek.com/en/operating-locations/landing-gear/kitchener
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Fleet Canada Inc.
Build-to-print aerospace manufacturer that specializes in airframe assembly, metal-to-metal bonding, etc.
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Shimco North America Inc.
Shim manufacturer and special processing of aircraft parts.
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Trinity Aerospace Corporation
CNC machining and aerospace engineering services.
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Tristar Coatings Ltd.
Manufacturer of solvent and waterborne primers and topcoats.
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(advancedmobilityproducts.com)
Project Title: Development of Safe and Reliable Rechargeable Energy Storage System (RESS) for a Solar Battery Electric UAS
Project Description: The project is to develop Safe and Reliable RESS for Superwake's Unmanned Aerial Vehicles (UAV) commercial applications. As Superwake begins its drive towards commercialization of its product, the need for conformity to regulatory standards is critical to the success of the product. This project focuses on a product conformity related to a regulatory framework such as Transport Canada Advisory Circular (AC) No. 922-001 – Remotely Piloted Aircraft Systems Safety Assurance. More specifically, a more complex RESS is required in advanced operations such as beyond visual line of sight (BVLOS), flying in controlled airspace and near people.
Environmental Impact: Low carbon footprint and replacement of aero vehicles that run on fossil fuels. The use of smaller solar battery electric drones can replace some applications of small, manned utility aircraft used in commercial applications. The cost to operate these drones would be substantially lower using solar battery electric drones.
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Project Title: High Altitude Platforms –Autonomous Flight Powered Using Wireless Power Transmission
Project Description: The project is part of a feasibility study to fly an uninhabited aircraft for very long, multiday missions by providing it with power using a mix of wireless power transmission and solar power. Power is transmitted as microwave energy from a ground-based transmitter and sent to a receiver that is attached to the lower surface of the aircraft wing, which converts it to DC power. The DC power will be used to drive electric motors on the airplane for propulsion, to power the payload and control systems and to charge standby energy-storage units. The project includes modelling, wireless power transmission flight testing using small uninhabited aircraft and performing a life-cycle assessment of high-altitude platforms.
Environmental Impact: Reduced emissions using alternate clean power source.
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Project Title: Airline Fuel Efficiency using Predictive Analytics
Project Description: In this project, use of flight time metrics will in turn develop efficient fuel- consumption prediction models using the advances in data training & machine learning historical data sets, while also applying external variables such as winds, precipitation and traffic congestion.
Environmental Impact: The development of optimal flight paths will enable fuel savings, reduce emissions and carbon footprint of the industry.
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Project Title: Enabling Circular Economy through Autonomous Repair and Remanufacturing of High-Value Gas Turbine Blades using Intelligent Laser Directed Energy Deposition
Project Description: The project focuses on the repair and restoration process of high-value turbine blades by combining the principles of Industry 4.0 through intelligent LDED-PF based AM. Material characterization work in this project includes feedstock analysis, microstructural analysis, mechanical testing and Non Destructive Testing (NDT).
Environmental Impact: The energy consumption and carbon footprint of using LDED to repair and remanufacture a turbine blade is substantially lower than manufacturing a new turbine blade.
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Project Title: Developing Ultra-lightweight Composite Propeller for Aerospace Applications
Project Description: The purpose of this project is to develop a low rotational mass moment of inertia propeller, which takes advantage of composite Tailored Fibre Placement (TFP) technology in conjunction with flexible tooling. Such a propeller will reduce the loads and stresses experienced by the aircraft powertrain – thereby extending the life of the powertrain components.
Environmental Impact: Lightweighting will create a reduction in greenhouse gases as we enable the reduction of weights and electrification of various transportation industries including aerospace, defence, Urban Air Mobility, UAVs and space vehicles.
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Project Title: Arctic Shoreline Mapping Pilot
Project Description: The purpose of this project is to supply the Department of Environment and Climate Change Canada (ECCC) with high-definition aerial imagery and video of shoreline regions in the Canadian Arctic, which will be used to segment the shoreline into a digital model. Superwake will join a team from ECCC in the Arctic in Summer 2023 to test the effectiveness of their long-endurance solar-powered remotely piloted aerial systems (RPAS) for this application. This project is part of a larger effort by ECCC to evaluate various coastal mapping methodologies, comparing satellite imagery and RPAS to helicopter-based operations, which form the baseline.
Environmental Impact: Superwake RPAS offers a reduced fuel consumption in the operations, versus the current helicopter option.
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Project Title: Chromate-free, Solvent & Water Based Primers and Integral Fuel Tank Coating for the Aerospace Market
Project Description: This project will allow testing and certification steps to commence on Tristar Coatings blends of chrome-free water and solvent-borne products.
Environmental Impact: This project aims to eliminate the chromates in the primers which will greatly reduce the exposure of all workers involved in the manufacturing, spraying as well as in the shipping and repair processes. Water-based primers greatly reduce VOCs at the manufacturing and end-use points.
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Project Title: Developing a Passive Icephobic Coating for Dash 8-400 Propellers
Project Description: Ice is one of the significant challenges that the aviation industry faces. Ice increases the weight of planes, but more importantly changes the aerodynamic profile of wings and propellors. There are two main pathways to reduce the effects of ice: to actively control the ice through heat or mechanical energy during flights, or to provide a passive coating that will allow ice to shed at low kPa. Zentek has developed a patent-pending passive icephobic coating that will be assessed and optimized for the Dash 8-400 propellers.
Environmental Impact: A passive icephobic coating on a propeller will improve safety, reduce the energy of in-flight de-icing and reduce the complexity of the current active systems that require regular maintenance.
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Nancy Barber
President
Women in Aerospace Canada
An aerospace senior executive with over 20 years of in-depth experience in operations, supply chain, and program management, Nancy Barber has spent much of her career in a product development environment involving large-scale clean sheet commercial and business aircraft programs. Nancy owns her own consulting business, Barber Complete Consultancy Inc, and is currently active in the aerospace industry, focused on leadership development, mergers & acquisitions, commercial strategy, product strategy and business development.
Prior to Nancy establishing BCC Inc., she held the position of Chief Operating Officer, Bombardier Business Aircraft, responsible for planning, assembly, and delivery of the Learjet, Challenger, and Global business aircraft as well as the industrialization strategy of Bombardier’s operational footprint. Nancy also held the role of Vice President, responsible for the Global 7500 and Global 8000, and New Aircraft Studies, where she led proactive management or program milestones and cost commitments supporting the ramp up of the Global 7500 aircraft, the largest purpose-built business aircraft world-wide, and its successful entry into service in 2018.
Nancy is a passionate promoter of women in aerospace serving as a mentor, coach, and speaker. In 2020, Nancy was named one of Canada’s Top 100 Most Powerful Women, and the Northern Lights Aero Foundation awarded her with the Elsie Award for Business in recognition of her outstanding contributions to aviation and aerospace in Canada.
In June 2022, Nancy was appointed President of Women in Aerospace Canada, a not-for-profit organization dedicated to expanding women’s opportunities for leadership and professional development as well as increasing their visibility in the aerospace community by creating a professional network in Canada and across the globe.
Nancy graduated with an Honors Bachelor of Arts degree from the University of Waterloo and has successfully completed the Queen's University Executive Leadership Program. She is published in the Journal of Sport Management as well as the Canadian Medical Association Journal.
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KOSS AEROSPACE
Koss Aerospace provides complete manufacturing solutions to the aerospace and defense industries, offering high speed multi axis machining, assemblies, kitting, metal finishing and vertically integrated services.
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Pursuit Aerospace
Manufacturer of complex aircraft engine components that are developed through highly integrated processes.
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RAMPF Composite Solutions Inc
RAMPF Composite Solutions designs and manufactures complex composite components and structures for the aerospace, defense, consumer, medical and transportation industries.
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Vac Aero International
VAC AERO is a leading vacuum furnace manufacturer, vacuum heat treating and coatings service provider to Aerospace and high-tech industries worldwide.
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