The development of a commercial airliner is a lengthy and complex process- one that mainly
encompasses design, prototype manufacturing, testing, certification, entry into serrvice,
and fleet support. This video provides a brief overview of the development cycle of modern
commercial airliners and the development time and costs of modern Boeing and Airbus aircraft.
There are three main design phases: conceptual, preliminary, and detailed. In the first phase,
the conceptual sketch of the aircraft is laid out, including aerodynamics, propulsion, performance,
structure, and control systems. In the preliminary design phase, the set for the aircraft.
Computational and wind-tunnel analysis of structural and control components
is performed. In the detailed design phase, the fabrication aspects of the design are finalized.
Flight simulators are then used to test the dynamics of flight.
It is noteworthy that the official launch of the
aircraft may occur sometime during the design phase.
Next up, is development of a prototype. An aeronautical prototype is built to test (both on
the ground and in flight) the new functionalities that must be implemented in the mass-produced
aircraft. The manufacturers simplify processes and requirements with a diverse team of professionals.
Different areas of design, production, supply chain, and marketing must work together to
achieve the goal. During the manufacturing stage, changing circumstances may require
people from different areas to make efficient decisions and ensure a continuous workflow.
The processes and controls are streamlined to apply to the mass-produced aircraft.
Once a prototype is built, testing and certification follows.
This process is a major challenge in developing a
commercial airliner. The manufacturer goes through a lengthy list of ground
and in-flight tests that must pass set criteria to be eligible for certification.
Not only are the design and functionality of individual components scrutinized,
but the processes and methods the manufacturers follow also go through the certification process.
If all goes well in certification, then the manufacturer must prepare for the aircraft’s entry
into service. This requires delivery tests and adequate training of personnel. The manufacturer
also provides fleet support to the aircraft during its operational life with the customer.
While fleet support contracts may significantly vary between customers,
design changes to the airframe remain the manufacturer’s responsibility.
So what does all of this cost?
Well, the development cycle of commercial airliners takes a
long time and incurs huge costs for manufacturers.
As we’ve seen with most new aircraft types in the past few decades,
it’s common for the certification process to take much longer than
planned. The development of the Boeing 787 Dreamliner, due to its composite design,
was estimated to complete in five years at the cost of $5.5 Billion.
However, several delays later, it took nine years for Boeing to
get the aircraft to the market, with an expenditure of over $22 Billion.
On the Airbus side, the A350 was delayed by over two years and
cost nearly $10 Billion as opposed to the initial estimate of $5.3 Billion.
The four-engined A380 was estimated to be $11.3 Billion. However, with nearly
three years of delay, the superjumbo cost Airbus a whopping $33.9 Billion.
So with all of this information presented,
what do you think about the development cycle of commercial airliners? Do the
delays and cost overruns surprise you? Leave a comment and let us know!
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