Aviation Maintenance Efficiency: A study on the Design and Analysis an Ergonomic Helicopter Maintenance Platform with Design Thinking

Year 2026, Volume: 07 Issue: 01, 21 - 34

Burhan Şahin , Merve Karataş

Abstract

In the aviation industry, the effectiveness, safety, and ergonomics of maintenance procedures are essential for ensuring the secure operation of aircraft. This research presents the design of a foldable and retractable maintenance platform aimed at enhancing the ergonomics and functionality of platforms utilized in helicopter maintenance tasks. In the study conducted using the Design Thinking methodology, the needs and working conditions of the maintenance personnel were prioritized, and a human-centered approach was adopted in the design process so that personnel weighing 120 kg and 190 cm tall could work safely. The evaluation included three different materials: Al 7075, steel and titanium. As a result of the static analysis performed for each material, a maximum stress of 330 MPa was achieved with the 2 mm thick Al 7075 material, which was considered safe by remaining below the yield strength of 503 MPa. Furthermore, the structure was optimized in terms of both strength and lightness by incorporating U-profiles into the platform design. Simulations confirmed that the developed platform will facilitate safe operations for maintenance technicians while increasing overall operational efficiency. This research seeks to address existing gaps in literature by offering ergonomic design solutions within the realm of aviation maintenance. The design exemplifies the effectiveness of the Design Thinking approach in the aviation maintenance sector and proposes a practical solution to enhance maintenance processes.

Keywords

Helicopter maintenance , design thinking , U-profile design , structural analyze , foldable mechanism

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