CERTO AEROSPACE

Certo appoints Randle as lead design consultancy on coaxial CAPSTONE UAV project

British engineering innovation consultancy, Randle Engineering, has been engaged to support Certo Aerospace Technologies with the development of the larger variants and heavy fuel (HF) versions of its heavy lift, uncrewed helicopter design, CAPSTONE. 

Currently in its third year of flight trials under CAA authorisation, CAPSTONE is a coaxial twin-rotor aircraft which is more efficient and scalable by design than other traditional helicopters and multi-rotors. Capable of carrying 300kg of payload, the prototypes have been tested in various Ministry of Defence flight trials and, in consequence, Certo is now collaborating with BAE Systems in a new competitive tender for the forthcoming multi-year MOD programme, Project NYX.

Randle Engineering is working on various key areas of the development pathway, all with the overarching mission to preserve and expand the optimal ratio of payload mass to maximum take-off weight, which is already at 50%. The Randle team is contributing specifically in the design of the aerodynamic airframe structures, HF engine integration and driveline systems. 

Computer-aided design (CAD) has been central to the Randle design effort and linear static analysis used to define load cases. Modal analysis helped evaluate force isolation and vibration response, while non-linear impact analysis was conducted to assess impact behaviour. FEA simulations were performed using Solidworks with OptiStruct FEA used as required to optimise the mass of the sub-systems.

Designed to save and protect lives across defence, logistics, disaster response and energy sectors, Certo’s CAPSTONE project reflects the UK’s growing engineering innovation, IP and industrial strength in the autonomy sector. Randle Engineering’s important contribution further demonstrates the robustness of the UK’s engineering design industry and the value that established engineering design enterprises can bring to new demand signals, such as the increasing calls for UAVs in applications such as disaster relief, defence and logistics. 

Ally McMahon, chief executive officer at Randle Engineering, said: “This type of cutting-edge project is perfect for our team, given our track record in innovation across the automotive and aerospace sectors. Our approach to engineering is firmly based on first principles. We solve new challenges like this with a clean sheet of paper, rather than trying simply to adapt off-the-shelf concepts that may be wholly unsuitable.” 

McMahon continued: “With two contra-rotating main rotors on top, and no tail rotor, CAPSTONE’s form factor not only reaps a significant energy advantage but also makes the overall length of the aircraft at least 33% smaller than a conventional helicopter of the same lift capability.  Another advantage of this modular design includes that it allows for rapid re-rolling from CASEVAC to construction, from firefighting to famine relief and across a multiplicity of military roles including logistics and submarine detection. 

“We are also learning from the advanced aerodynamic analysis we are conducting with academics that the particular coaxial control system employed on CAPSTONE has distinct advantages in real-world weather conditions and operational military scenarios.” 

Justin Tooth, CEO at Certo Aerospace, added: “Having Randle Engineering as our lead design consultancy on these highly challenging and specialised areas of our development pathway has proved a significant boost to our rate of progress. The Randle engineers bring excellent experience in design and project management that are highly complementary to our own. Contributing at this level to a wholly novel aircraft class is also really rewarding professionally, so it is very encouraging to see our colleagues at Randle enjoying this journey as much as we do!”

Vivaero