Aerospace

Cascon engineers have deep experience in the design, development, and manufacture of pumps tailored for use in aerospace applications. Whether for general aviation or manned space flight, our products are designed to perform flawlessly under the most demanding conditions.

In our unrelenting commitment to quality, we employ a robust requirements management system and a proven process that’s yielded exceptional results for dozens of customers over hundreds of development cycles. And while our process is clearly defined, we can easily integrate diverse client requirements for review, verification, and production control that may include gated design review, manufacturing plans, and detailed verification and acceptance test plans. We manage the complexity to deliver smoothly against rigorous client requirements – all while maintaining clear, open and comprehensive communication.

Product Examples

28 Volt IGR Fuel Metering Pump

Conventional and EFI Fuel Supply | Military Unmanned Aerial Vehicles

P-151, 151-D-151-1

28V Hydraulic Transfer Pump

Hydraulic System Charge Pump | Premier Business Jet Manufacturer

P-089, 89-D-051-1

Deionized Water Oxygen Generation Pump (OGA)

Environmental System Support Aboard the International Space Station (ISS) | Leading Supplier of Spacecraft Environmental Systems

P-085, 85-D-451

Deionized Waste Water Pump (WWP)

Environmental System Support Aboard the International Space Station (ISS) | Leading Supplier of Spacecraft Environmental Systems

P-086, 86-D-451

Deionized Water Delivery Pump (WPDP)

Environmental System Support Aboard the International Space Station (ISS) | Leading Supplier of Spacecraft Environmental Systems

P-87, 87-D-451

28 Volt Brushless DC Coolant Pump

Galden Heat Transfer Fluid Pump for Spacecraft Crew Capsule | Industry Leading Spacecraft Environmental System Supplier

P-264, 264-D-001

28 Volt Coolant Pump

Coolant Circulation for Military and Commercial Avionics | Manufacturer of Aerospace Cooling Systems

P-212, 212-D-001

Gear Driven Lubrication and Scavenge Pump

Power Transfer, Lubrication, Cooling and Scavenge for Diesel Aircraft Engine | World Leading General Aviation Engine Manufacturer

P-292, 292-D-201

Two-Circuit Scavenge Pump

High-Speed Aircraft Generator Oil Scavenge | Manufacturer of Aircraft Generators

P-186, 186-D-001

12 Volt Duplex Fuel Pump for Aircraft

Redundant Fuel Supply for General Aviation Aircraft | Manufacturer of Aircraft

P-160, 160-D-031

400 Hz AC Coolant Pump

Military Aircraft Electronics Cooling | Leading Supplier to the Aerospace Industry

P-254, 254-D-001

Refrigerant Pump, Airborne Electronics Cooling

400 Hz AC Drive Motor | R1234z(e), R134a | Aircraft Engine OEM

P-328, 328-D-001

28 Volt Hermetic Fuel Pump

Fuel Supply for Improved Tactical Air Launched Decoy (ITALD)| Military Systems Integrator

P-088, 88-D-001

Custom Fuel Pump for Military UAV Turbojet

Electronically controlled, precision custom fuel metering pump | UAV turbojet engines

P-062, EX-921D

Four-Output Lubrication Pump

Lubrication and Sealing for Satellite-Based Cryogenic Compressor | Satellite Technology Integrator

P-97, 459

Lubrication & Scavenge Pump

Aircraft Gas-Turbine Lubrication and Scavenge | Manufacturer of Business Class Jet Engines

P-95, 324

Series 100 High-Reliability Fuel and Coolant Pump

Fuel & Coolant Supply | Aircraft, eVTOL, UAV and other High-Reliability Industrial Applications

P-300, 100-XaXbXc-XdXeXf

Customer Objective

Cascon was approached by a leading supplier to the aerospace industry and U.S. space flight programs with a compelling challenge: the development of a pump to circulate ultra-low viscosity, high density heat transfer fluid in a cooling system for manned space flight applications. The customer’s development objectives for the pump called on Cascon to:

Moderate costs by employing applicable commercial design strategies
Design the pump for close integration with the overall system design
Engineer the design for durability to withstand heavy shock and vibration loads
Ensure reliability for the duration of an extended operational lifespan

Cascon Solution

The first step in any Cascon custom design and development effort is a clear understanding of the customer’s requirements. Experience gained over hundreds of design cycles has helped us develop a flexible and comprehensive requirements management system. The nearly 150 separate requirements for this critical application were tracked for clarity of understanding and compliance verification through the design and prototype phases of the program.

When this project began, neither Cascon nor the customer had experience with the unique heat transfer fluid, and there was little public domain data available on its tribiological properties. In an effort to ascend the steep learning curve, we commissioned an inexpensive 5,000 hour test using four existing Cascon pump models with design similarities to the customer’s specification.

Given its importance to the success of the project, Cascon worked to secure a brushless DC drive motor capable of withstanding extreme vibration and shock loads. Working through established relationships with trusted suppliers, we sourced a custom motor, constructed primarily with components and processes drawn from a commercial manufacturing line. This budget-friendly sourcing solution was then finalized with the introduction of traceability and process control parameters to satisfy the client’s strict requirements for manned space flight applications.

Cascon completed preliminary design review (PDR) and critical design review (CDR) presentations and reports to eliminate potential oversights, and to document any potential risks prior to prototype manufacture. We then manufactured prototype pumps for testing, analysis, and verification against project requirements and cost objectives.

Following the prototype phase, the first flight build was completed with minor design adjustments to accommodate requirement revisions, and to incorporate final improvements. The pump is slated for its first crewed spacecraft flight test in late 2019.

Pump Features

Integrated design: Custom flange for direct manifold mounting, with an integrated inlet filter to conserve space and provide easy access.
Precision stellite gerotor pump element: Reliable gerotor performance reduces weight while ensuring durability.
Hybrid ceramic ball bearings: Precision design for reliable performance.
High reliability 28 volt brushless DC motor: Tested technology ensures reliable operation under the most demanding circumstances.
Durable HED sensor board: Designed to perform through continuous shock, vibration, heat and atmospheric changes.