AS 350 HELICOPTER A “DESIGN TO COST” EXERCISE

The main objective aimed at for the development of the new AEROSPATIALE 5/6 seat helicopter, the AS 350, was the reduction in production and operating costs. Right from the design stage, the search for the most economical solutions, carried out with the help of production engineers, integrated into the design team, has called for the creation of new techniques and the application of new technology. Among these are: (1) the starflex rotor head, (2) mechanically produced glass/resin composite blades, (3) the two-bladed tail rotor molded on a single torsion strip, also made of glass/resin composite material, (4) the rotor flexible suspension based on laminated elastomer, and (5) the thermo-formed plastic canopy. After the project conceptual phase completion in 1972, the aircraft was developed in an autonomous production unit, (or “island”) to benefit from the advantages a small team, grouped together but supported by the technical depth of the Engineering and Production Departments. In spite of the numerous innovations and the additional work for cost analysis and design finalizing, it has been possible to complete the development in a relatively short time while keeping within budget limits. The first flight was made on June 30, 1974 and the first production aircraft should be delivered in mid-1977. In comparison with the Alouette 2 and Gazelle the AS 350 requires nearly 3.5 times fewer production hours for 3.5 times fewer number parts. The cost of the equipment items, some of them found in the general or automotive industry, is also reduced. While the selling price may not fully reflect the reduction achieved in production costs, due to amortization of the general expenses, the operating costs, however, will be low right from the entry into service, due to the practically nil number of life limited parts, very extended T.B.O.’s and the low cost of general maintenance, spares and labor. The cost per unit weight carried should normally, be about three times lower than with the Alouette 2.