Designing and constructing an aircraft

Small aircraft can be designed and constructed by amateurs as homebuilts. Other aviators with less knowledge make their aircraft using pre-manufactured kits, assembling the parts into a complete aircraft.

Most aircraft are constructed by companies with the objective of producing them in quantity for customers. The design and planning process, including safety tests, can last up to four years for small turboprops, and up to 12 years for aircraft with the capacity of the A380.

During this process, the objectives and design specifications of the aircraft are established. First the construction company uses drawings and equations, simulations, wind tunnel tests and experience to predict the behavior of the aircraft. Computers are used by companies to draw, plan and do initial simulations of the aircraft. Small models and mockups of all or certain parts of the aircraft are then tested in wind tunnels to verify the aerodynamics of the aircraft.

When the design has passed through these processes, the company constructs a limited number of these aircraft for testing on the ground. Representatives from an aviation governing agency often make a first flight. The flight tests continue until the aircraft has fulfilled all the requirements. Then, the governing public agency of aviation of the country authorizes the company to begin production of the aircraft.

There are few companies that produce aircraft on a large scale. However, the production of an aircraft for one company is a process that actually involves dozens, or even hundreds, of other companies and plants, that produce the parts that go into the aircraft. For example, one company can be responsible for the production of the landing gear, while another one is responsible for the radar. The production of such parts is not limited to the same city or country; in the case of large aircraft manufacturing companies, such parts can come from all over of the world.

The parts are sent to the main plant of the aircraft company, where the production line is located. In the case of large aircraft, production lines dedicated to the assembly of certain parts of the aircraft can exist, especially the wings and the fuselage.

When complete, an aircraft goes through a set of rigorous inspection, to search for imperfections and defects, and after being approved by the inspectors, the aircraft is tested by a pilot, in a flight test, in order to assure that the controls of the aircraft are working properly. With this final test, the aircraft is ready to receive the " final touchups" (internal configuration, painting, etc.), and is then ready for the customer.