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- Monday-Friday: 9am to 5pm
- Saturday: 10am to 3pm
- Sunday: Closed
Request a Quote
Looking for a quality and affordable builder for your next project?
Call Us
+1 983-212-4655
Working Hours
We are happy to meet you during our working hours. Please make an appointment.
- Monday-Friday: 9am to 5pm
- Saturday: 10am to 3pm
- Sunday: Closed
Next-Generation Aviation & Aerospace Engineering Solutions
Consac (consac.systems) delivers specialized, high-fidelity engineering expertise across hypersonics, urban air mobility (eVTOL), autonomous unmanned systems, liquid hydrogen cryogenics, and MBSE digital thread architectures. Supporting tier-1 primes and OEMs across the United States, Canada, Norway, India, and globally.
Global Operations Telemetry
Macroeconomic Convergence Driving Aerospace Design Outsourcing
This section analyzes the structural economic shifts mandating specialized external engineering partnerships. The global aerospace and defense sector is expanding from $402.75 Billion in 2025 to over $846.30 Billion by 2035. Concurrently, specialized engineering services outsourcing is surging at an unprecedented 24.9% CAGR—driven by severe talent scarcity in hypersonic thermodynamics, urban air mobility safety case generation, and MBSE software integration.
Global Market Projections ($ USD Billions)
2023 - 2035 HorizonInteractive Chart: Compare baseline vs projected market expansion across key aerospace domains.
Aerospace Sector CAGR & Market Data
| Sector / Segment | Baseline | Projected | CAGR Rate |
|---|---|---|---|
| Global Aerospace Market | $402.75 B (2025) | $846.30 B (2035) | 7.71% |
| Aerospace & Defense Sector | $2.70 B (2025) | $4.90 B (2035) | 6.10% |
| Engineering Outsourcing | $116.90 B (2023) | $560.90 B (2030) | 24.90% |
| Engineering Services Industry | $1.14 T (2025) | $1.60 T (2030) | 4.60% |
Specialized computational fluid dynamicists and flight safety engineers take 10+ years to cultivate internally.
Engineering outsourcing growth (24.9%) outpaces general engineering market growth by 5x.
Five Specialized Aerospace Engineering Silos
Consac organizes its technical design services into five core engineering repositories. Select any silo below to inspect detailed methodology, computational solvers, safety frameworks, and regulatory compliance standards. Click "Inspect Engineering Spec Brief" to view technical details in an interactive drawer.
Hypersonic Flight & Scramjet Flowpath Engineering
Flight at speeds above Mach 5 involves severe high-temperature gas dynamics, non-equilibrium chemical reaction kinetics, structural ablation, and shock-wave boundary layer interaction (SBLI). Consac delivers 3D Rectangular-to-Elliptical Shape Transition (REST) intakes, unstart shock-system stabilization, and thermal protection system (TPS) engineering.
⚡ REST Intake Geometry & SBLI Mitigation
Hypersonic scramjets require decelerating incoming airflow to manageable supersonic speeds without causing flow blockage ("engine unstart"). Consac designs 3D REST intakes that mitigate boundary layer buildup in corner regions and maintain high total pressure recovery ($P_{0,2}/P_{0,1}$).
🔥 Thermal Protection Systems (TPS) & Materials
Atmospheric reentry and steady-state Mach 7 flight generate stagnation temperatures over 2,000°C. Consac designs multi-layer TPS architectures utilizing oxidation-resistant Carbon-Carbon (C-C) composites, CVD Silicon Nitride ($Si_3N_4$) environmental barriers, and high-temperature dynamic seals.
Scramjet Intake Architecture Generations
| Generation | Inlet Flow Field | Aerodynamic Drag Profile | Historical / Modern Target |
|---|---|---|---|
| Gen 1: Axisymmetric | Conical spike, 2D compression | High wave drag & cowl spillage | Hypersonic Research Engine (HRE) |
| Gen 2: 2D Planar | Flat ramp, single-plane deflection | Corner flow boundary accumulation | National Aero-Space Plane (NASP) |
| Gen 3: 3D REST (Consac Core) | Rectangular-to-Elliptical Curved Transition | Minimal corner drag & shock reflection | X-51A Waverider / Operational Hypersonics |
eVTOL & EASA SC-VTOL-01 Enhanced Certification
Electric Vertical Take-off and Landing (eVTOL) aircraft operating over densely populated urban areas must satisfy EASA's stringent SC-VTOL-01 "Enhanced" category standard. This mandates proving that catastrophic single-point failures are extremely improbable ($< 10^{-9}$ per flight hour) and that safe flight and landing can be maintained following One Motor Inoperative (OMI) events.
🛡 Distributed Electric Propulsion (DEP) Redundancy
Because eVTOLs generally lack conventional autorotation, rotor torque balance must be preserved electronically. Consac designs fault-tolerant dual-stator electric motors, isolated dual-bus high-voltage power networks, and automatic thrust re-allocation flight control laws.
🐦 High-Velocity Bird Impact & Crashworthiness
Under CS-23/25 and SC-VTOL-01, aircraft must demonstrate structural survival under bird impact scenarios without losing Continued Safe Flight and Landing (CSFL) capabilities. Consac models high-strain dynamic impacts using explicit FEA solver routines.
Unmanned Systems & JARUS SORA BVLOS Risk Assessment
Integrating autonomous uncrewed aircraft into non-segregated airspace requires executing standard risk models. Consac guides drone manufacturers through Joint Authorities for Rulemaking on Unmanned Systems (JARUS) SORA methodologies, determining Ground Risk Class (GRC), Air Risk Class (ARC), and implementing active technical mitigations to lower the final Specific Assurance and Integrity Level (SAIL).
📈 GRC / ARC Reduction & Parachute Mitigations
High initial Ground Risk Class values can stall commercial deployment. Consac integrates ASTM F3322-18 compliant ballistic parachute recovery systems and geofencing containment logic that reliably reduce initial GRC scores by 2 to 3 tiers.
📜 ISO 21384-3 Operational Airworthiness Compliance
We establish quality management processes and software verification workflows satisfying ISO 21384-3, streamlining BVLOS waivers across FAA Part 107/135 and EASA Specific Category operations.
Sustainable Aviation: Cryogenic Liquid $H_2$ & Hybrid Electric
Transitioning commercial transport aircraft to zero carbon emissions requires liquid hydrogen ($LH_2$) stored at 20 Kelvin (-253°C). Consac develops lightweight vacuum-insulated cryogenic fuel tanks, active boil-off gas management systems, fuel cell balance-of-plant integrations, and analyzes operational data from Norway's Avinor Zero-Emission Sandbox.
✼ Vacuum Multi-Layer Insulation (MLI) & Boil-Off
Liquid hydrogen volumetric density requires minimizing heat leak rates into fuselage-integrated tanks. Consac models thermodynamic phase changes and designs multi-barrier vacuum MLI jackets that maintain boil-off rates under 0.15% per day.
⚡ Norwegian Sandbox Flight Test Data Analysis
Utilizing flight test telemetry from regional Norwegian electric routes (BETA ALIA & Electra EL9 platforms), Consac optimizes megawatt-class fast charging protocols and cold-weather battery thermal management units.
MBSE System Architecture & iFEM Digital Twins
Legacy document-centric systems engineering introduces expensive requirement gaps late in physical flight testing. Consac constructs unified SysML digital threads that link top-level airworthiness requirements directly to mechanical, electrical, and software models in strict alignment with SAE ARP4754A.
💻 SysML Single Source of Truth
Our MBSE architecture enables automated multi-domain trade studies prior to physical prototyping. Verification and validation (V&V) matrices are updated continuously, cutting late-stage engineering rework costs by up to 85%.
🔄 Structural iFEM Digital Twins & HUMS
Combining Health and Usage Monitoring Systems (HUMS) with inverse Finite Element Methods (iFEM), Consac develops structural digital twins that predict airframe fatigue and remaining useful life (RUL) in real-time.
Interactive Analytical Solvers & Trade-Off Models
Explore Consac's rapid analytical capabilities. Below are three interactive computational solvers: an aerothermal stagnation heating calculator based on the hypersonic Fay-Riddell fluid dynamics equation, an MBSE software migration ROI calculator, and an aircraft fuel energy density & mass fraction estimator comparing liquid hydrogen, lithium-ion batteries, and standard Jet-A fuel.
Hypersonic Heating Solver
Fay-Riddell Stagnation ModelMBSE Program ROI Solver
Rework & Schedule CompressionPropulsion Mass Fraction
Energy Density & Range EstimatorMulti-National Certification Frameworks
Achieving timely airworthiness approval requires deep familiarity with regional regulatory bodies. Consac operates across four primary international regulatory hubs: the United States (FAA), Canada (TCCA), Norway (CAA Norway), and India (DGCA), alongside global EASA compliance alignment.
United States
FAA Part 23/25 transport certification, Part 33 engine standards, and MIL-SPEC compliance for US DoD defense procurement programs.
Canada
Transport Canada Civil Aviation (TCCA) CAR Standard 505 Design Approval Delegation and Canadian Controlled Goods Program (CGP) clearance.
Norway
CAA Norway / EASA regulatory sandbox execution for zero-emission aircraft, regional hydrogen corridors, and harsh cold-weather testing.
India
Directorate General of Civil Aviation (DGCA) CAR 21 Subpart J Design Organisation Approval (DOA) and military CEMILAC airworthiness clearance.