DIAMOND AIRCRAFT INDUSTRIES

D-JET (In Development)

 Two pilot seats in the front & three
passengers can be seated in the cabin.
 Baggage area is provided in the cabin
behind the rear seats, and baggage areas
are available in the nose and tail of the
aircraft

AIRCRAFT (In Production)

 DA 20  DA 42
 DA 40  DA 50
Infotech Engagement:

• Started in Apr 2008, with onsite team of 08

• Offshore work started in Jul 2008, with a team of 05

• Offshore team ramped up to 25 to meet customer schedules

• Completed work packages as on date: ~ 98 (Offshore)

• Total offshore hours worked as on date: ~ 5320 hrs

• Environment/Tool used: SMARTEAM (PDM) & CATIA V5 R18

SP7
Nature of work:

• Creating Parametric Models, building assemblies within PDM

environment- Onsite task

• Creating manufacturing drawings for composite, metallic,

tubes, foam and leather parts using Notes and parameter
scripts

• Creating Installation drawings and Assembly drawings for

various ATA chapters using BOM scripts

• Creation of Flat Patterns for Composite Cores using

composite module – Onsite task

• Creation of 3D Electrical harness models and installation

drawings- Onsite task
ATA Chapters worked on:

• 24 Electrical Power

• 25 Equipment/ Furnishings

• 27 Flight Controls

• 31 Indicating/ Recording System

• 32 Landing Gear

• 55 Stabilizers

• 57 Wings

• Ground Testing
Diamond Documents

• DJM-CM-150 DRAFTING STANDARDS

• DJM-PS-099 PROCESS SPEC INDEX
• DJM-MS-099 MATERIAL SPECS
• DIAMOND MATERIAL CATALOGUE – CATIA V5
• CATIA Scripts for Notes, BOM, Frame & Title, Etc.
DJM-PS-099 - Diamond Process Specs

DJM-PS-141 Storage and Handling of Dry Cloth

DJM-PS-142 Storage and Handling of Uncured Resin
DJM-PS-143 Storage and Handling of Prepreg Materials
DJM-PS-144 Storage and Handling of Core Materials
DJM-PS-300 Wet Lay-up of Fibre Composites
DJM-PS-301 Preparation of Moulds
DJM-PS-304 Application of Lightning Strike Mesh
DJM-PS-360 Vacuum Bagging and Curing of Prepreg Laminates
DJM-PS-380 Cutting and Trimming of Composite Parts
DJM-PS-400 Cutting and Shaping of Core Materials
DJM-PS-401 Thermal Conditioning of Foam Core
DJM-PS-403 Potting of Honeycomb Core
DJM-PS-420 Thermal Forming of Foam Core
DJM-PS-520 Assembly of Composite Parts by Adhesive Bonding
DJM-PS-521 Surface Preparation for Bonding
DJM-PS-540 Tightening of Threaded Fasteners and Connection
DJM-PS-099 - Diamond Process Specs
DJM-PS-541 Installation of Solid Shank Rivets
DJM-PS-542 Installation of BLIND RIVET
DJM-PS-543 Installation of Pins and Collars
DJM-PS-544 Installation of Threaded Fasteners
DJM-PS-562 Bushing Wet Installation in Composite Structure
DJM-PS-565 Wet Installation of Fasteners
DJM-PS-566 Drilling and Finishing of Fastener Holes in Composite Structure
DJM-PS-567 Surface Preparation for Bonding of Metallic Components
DJM-PS-580 Sealing
DJM-PS-581 Surface Preparation for Sealing
DJM-PS-582 Application of Sealants
DJM-PS-590 Control Cable Fabrication
DJM-PS-591 Control Cable Installation
DJM-PS-592 Installation and Retention of Bearings and Bushings - Metallic Structure
DJM-PS-099 - Diamond Process Specs

DJM-PS-593 Installation of Shrink Fit Bushings – Metallic Structure

DJM-PS-594 Cleaning and Pressure Testing of Tubing
DJM-PS-595 Cleaning and Inspection of Oxygen system components
DJM-PS-596 Non-Structural Bonding
DJM-PS-620 Finishes, Coatings and Treatments of Metal Parts
DJM-PS-621 Cleaning and Conversion Coating of Aluminum Alloys
DJM-PS-622 Cleaning of Carbon and Low Alloy Steel
DJM-PS-623 Cleaning of Corrosion Resistant Steel
DJM-PS-630 Preparation and Painting of Metallic Components
DJM-PS-640 Preparation and Painting of Composite Surfaces
DJM-PS-700 Visual and Dimensional Inspection
DJM-PS-800 Metal Fabrication Processes
DJM-PS-821 Fabrication and Installation of Tubing Systems
DJM-PS-907 Cleaning, Handling, and Temporary Storage of Metallic Parts
DJM-PS-908 Part Marking
DJM-PS-910 Electrical Bonding and Grounding
Composite Material Spec
Drawing Notes
for Machined Parts

for Sheet Metal Parts

Notes for Composite Parts
Notes for Source Control Drawings

Notes for Assembly/ Installation Drawings

D-Jet Aircraft

H-STAB

RUDDER WING

DORSAL FIN

PAX SEATING
D-NOSE

VENTRAL FIN
ENGINE BAY

Y-DUCT
FAIRING NOSE

LANDING GEAR FWD BULK HEAD

Hooke’s Joint Bracket (Machined Part)

Machined part Detailed as per Diamond standards

using GD&T
FWD Equip. Shelf RH (Sheet Metal Part)

Sheet Metal
Part Detailed
as per
Diamond
standards
using GD&T
 Flap Lower Skin, LH (Composite Part)

Composite part Detailed as per Diamond standards

showing Ply Representation with Foam core, Ply
Table and BOM

Wing Skin
(DJM-MS-101)

Foam Cores
(DJM-MS-401)
Composite Part Lay up Procedure

• MOULD PREPARATION AND APPLY GEL COAT

• APPLY RELEASE AGENT/ VAX ON MOULD FACE
• PLACE THE PLIES P10, P20, P30 … ON THE MOULD AS PER
THE PLY TABLE
• PLACE THE CORES/ INSERTS IF ANY
• PLACE THE PLIES P50, P60, P70…
• PLACE THE PEEL PLY AS INDICATED
• PLACE THE WICK AND POLYETHYLENE BAG FOR VACCUME
BAGGING PROCESS
• CURE THE LAY UPS IN THE OVEN/ AUTOCLAVE
• DEMOULD THE CURED PART
• TRIM AND FINISH THE COMPOSITE PART
• APPLY THE PAINT ON THE COMPOSITE PART
Retraction Actuator Assy (SCD Dwg)

Source Control Drawings (SCD) are made for the Parts coming from out side
Vendors/ Suppliers. These Drawings contain Manufacturer Name and Address
in the Notes area and marked as “SOURCE CONTROL DRAWING” on the
face of the drawing just above title block.
 SYS Conduit, LH FWD ( Tube Drawing)

Tube detailed drawing

containing Tube node
co-ordinates, Tube
node data calculated
by creating axis
system at one end.
SYS Conduit, LH FWD, Assembly (Tube Assy)
Tube assembly made by welding Lugs to the Conduit &
heat shrinks at both ends, all to be detailed as per
diamond standards showing welded symbols

Heat Shrink

Lugs
Electrical Bonding, Tail, Installation

Installation drawing made by showing all

surrounding supporting parts as reference, BOM
(run by BOM script), shown for all hardware and
stand offs
PAX Seat Installation

Seat back (with foam and leather)

Seat cushion (with foam and leather)

Arm Rest
Y-Duct Fairing Installation

Y duct fairing is being installed using hardware

with seals on all faces & being fixed with
Fuselage closure assembly & Wing assembly
Rudder Pedal Assembly

Bulkhead

Panel Frame

Pedal
Elevator Control Installation-V Stab

Spar V stab Aft

Spar V stab Mid

Bulkhead V stab FWD

 Flap Installation LH

Inboard Fitting

Outboard Fitting

Flap Assy
H-Stab, D-Nose Installation

Horizontal Stabilizer

D Nose
FWD Fuselage Longitudinal Restraint Mechanism