Custom Design
Standard equipment doesn’t always fit the mission.
When you’re dealing with unique airframe contours, tight hangar clearances, or changing compliance requirements, “close enough” equipment becomes a safety risk and a productivity drag.
SafeSmart Aviation designs, engineers, and manufactures purpose-built access and support solutions that integrate cleanly into your workflow, so teams move faster, work safer, and reduce the risk of aircraft damage.
Custom Case Study Summaries
Below are short summaries from real custom programs we’ve completed. Each summary highlights the challenge, what we built, and the outcome. If you’d like deeper technical detail, including drawings, specs, or a full case study, our team can walk you through what’s available.
Commercial Aviation
Speed, safety, and scale.
In commercial maintenance, time on the ground is lost revenue. We help airlines, MROs, and airports reduce turnaround time by replacing unstable ladders and improvised solutions with precise, aircraft-matched platforms built for repeatable, day-in and day-out use.
Royal Australian Air Force | C-17A Globemaster III Engine Access
The Challenge
Maintenance teams required a way to access the massive F117-PW-100 engines safely. Traditional scaffolding was slow to assemble and often obstructed hangar floor space.
What We built
A custom-engineered, height-adjustable aluminum docking system specifically contoured to the C-17A engine nacelles.
ThE Result
A significant reduction in setup time and a much safer working environment that allows technicians to perform dual-engine maintenance simultaneously.
United Airlines | Boeing 787 Engine Access
The Challenge
Technicians needed safe access to 115-inch engine structures, but standard ladders were unstable and non-compliant.
What We built
A modular, two-piece bridging platform contoured to the GEnx engines.
ThE Result
A stable, OSHA-compliant bridge over the engine that enables faster, safer maintenance.
Air Mauritius | Airbus A350 Fleet
The Challenge
Safe access to critical zones, doors, fuselage, and tail, across all A350 variants.
What We built
A coordinated family of height-specific platforms designed to cover the fleet.
ThE Result
A unified, efficient workflow for maintenance and cleaning teams.
Defense & Military
Mission readiness. Anywhere.
Military operations demand equipment that’s rugged, rapidly deployable, and adaptable to specialized aircraft requirements. We engineer solutions that stand up to field conditions while improving technician access, safety, and speed, without compromising the aircraft.
US Marines | MV-22 Osprey Tiltrotor
The Challenge
Reaching delicate nacelles at varying pitch angles in remote environments.
What We built
A two-piece, contouring aluminium platform with optional pneumatic or electric height adjustment.
ThE Result
Rapid deployment capability and safer engine access, even in austere conditions.
US Air Force | B-52H Stratofortress
The Challenge
Safely handling fragile bomb doors during the restoration of “Ghost Rider” from long-term storage.
What We built
A custom foam-lined rack mounted directly to the aircraft’s rolling chassis.
ThE Result
Safe removal and transport that supported completion 90 days ahead of schedule.
Rotary Aviation
Complex geometries. Precision fit.
Helicopters present tight-clearance access problems, from tail rotors and skids to sensitive composite surfaces. We solve these with platforms and docks that fit close, provide full coverage, and maintain safe standoff to help reduce the risk of contact damage.
HNZ / PHI Group | AW139 Split Tail Dock
The Challenge
Tight-clearance tail rotor access across multiple maintenance configurations.
What We built
A hand-manoeuvrable split tail platform with detachable stairs and height-adjustable castors.
ThE Result
Maximum flexibility, wheel in from either side for rapid access.
Ambulance Victoria | AW139 Heavy Maintenance
The Challenge
Handling heavy components safely during rotor checks and deep maintenance.
What We built
A heavy-duty rotor maintenance platform with a 500kg load rating and forklift or gantry loading capability.
ThE Result
Full-surround access and improved safety when handling heavy parts.
We Find a Way
Contact our team of experts today to discover tailored safety access systems and loading platforms that meet your unique needs—because your project deserves nothing less than the best in safety, efficiency, and innovation.
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