A Reasonable and Robust Response

In early 2022, Van’s Aircraft, the famed light-sport aircraft marque and maker of the perennially popular RV6/6A, RV7/7A, and numerous additional kit aircraft models, commenced subcontracting the manufacture of select aircraft parts to fabrication concerns utilizing laser cutting processes.

The decision to subcontract parts manufacturing was, according to Van’s: “ … made after completing a formal manufacturing process evaluation and extensive fatigue testing of materials used in the manufacturing process, with the purpose of increasing the production capacity for some parts during a period of high demand.”

Between February and June 2022, a significant number of Van’s customers reported cracks having formed in parts with laser-cut holes. The company immediately undertook corrective action, conducting testing of cracked parts for purpose of assessing the nature of the defects and devising corrective measures germane to such.

Van’s determined the parts of greatest concern to be:

• Vertical stabilizer, rudder, and elevator spars on all RV-7, RV-8, RV-9, RV-10, and RV-14 empennage/tail kits.
• Horizontal stabilizer spars in RV-7/8 empennage kits.
• Flap and aileron spars shipped early in the laser-cutting process, in RV-7, RV-8, RV-9, RV-10, and RV-14 kits.

Seeking to safeguard its customers and the larger aviation community, Van’s, on 04 July 2023, stated on its website: “We encourage people to pause building of the above specific kits that include laser-cut empennage/tail, aileron, and flap-spar parts. We will be replacing these components and providing further guidance. Even though testing of these specific parts is not yet complete, Van’s is erring on the side of caution by identifying those parts now and will recommend the replacement of these parts due to the relatively high loads carried by those specific parts. We will communicate directly with all affected customers concerning these parts via email this week, to inform those customers as to what steps should be taken. We are executing an initial run of replacement parts on our punch presses now and will be making additional production runs.”

The statement continued: “Our testing program for this issue is ongoing and focused on reviewing the various hole diameters and material thicknesses/types that were used to produce the laser-cut parts. These variables, as well as variations in manufacturing process parameters, can result in a marked difference in the potential for a crack to form in a given hole. We will prioritize testing and manufacturing of replacement parts based on these differences. We are also reviewing the metallurgy of the holes at the third-party test lab, in order to better understand the origin and cause of the observed cracks. From that, we will gain a greater understanding about these cracks and at what stages in the process they are formed (when cut, when dimpled, when riveted). We expect to receive those results soon, even before the full spectrum of overall testing is completed, and we will communicate that information when available.”

Updates pertaining to Van’s investigation of the defective parts and the results and solutions occasioned thereby were posted to the plane-maker’s website on 09 July, 12 July, 15 July, 21 July, and 12 August.

On 18 August, Van’s further updated its website, setting forth: “Progress in the testing program has been good and is still ongoing. Complete wing structures have been tested as well as continued testing of specific materials, holes, dimples, and fasteners in combination.

“We anticipate launching a web-based portal interface in early September that will allow customers to select which laser-cut parts they need to have replaced.  The portal will specify which parts are on the laser-cut list and the individual part counts for that associated kit. Customers will be able to specify which parts they wish to request replacements for, and to submit their request to Van’s Aircraft. More information about the portal will be released as we get closer to its availability.

“In addition, today Van’s published a reference document providing visual identification assistance for the purpose of identifying laser-cut and punched parts. You may access that document at this link. We will be adding information to this document over time, including additional examples. We welcome feedback, which can be sent to support@vansaircraft.com.

"We anticipate releasing our next update on or before September 5th."

FMI: www.vansaircraft.com