High Integrity Test Rigs

Precision test environments for reliable system validation

  1. AFD Systems
  2. What we do
  3. High Integrity Test Rigs

High Integrity Test Rigs

AFD Systems delivers high integrity test rig solutions designed to validate and verify the performance of complex structural systems across aerospace and defence platforms.

From concept through to full systems commissioning, our team combines advanced engineering expertise with in-depth domain knowledge to create reliable, data-driven test environments that enable safe and efficient system development.

Our technical expertise helps customers accelerate product validation, reduce risk and ensure compliance with the most demanding operational and regulatory standards.

Expertise you can trust

We provide a complete suite of test rig design and manufacturing services, supporting the full lifecycle of test system development from early feasibility to installation and commissioning.

Our team works closely with customers to design and deliver bespoke, high-performance rigs that replicate real-world conditions, ensuring components and sub-systems are tested under representative loads, pressures and dynamics.

We offer both design-only services and turnkey solutions, integrating mechanical, electrical and control systems to achieve precise test outcomes.

Our capabilities include:

  • Design and development of high integrity mechanical and hydraulic test rigs
  • Electrical and control system integration
  • Modelling, simulation and virtual testing
  • Pressure, vibration and environmental test systems
  • Full system build, commissioning and certification
  • Maintenance, upgrade and support services

Our experience spans aerospace, defence and industrial platforms, delivering test rigs for structures, actuators, propulsion systems and flight-critical sub-systems.

Our process and methodology

Our team brings together highly skilled engineers with subject matters experts to craft advanced test rig solutions that meet the highest standards of integrity and performance.

Our process integrates digital engineering, simulation and systems modelling to optimise rig functionality before manufacture, reducing rework and ensuring first-time results.

We partner and collaborate with other UK-based and trusted SMEs, such as High Integrity Systems, that specialise in Model-Based Systems Engineering (MBSE), embedded software engineering, and other system engineering specialisms, to deliver complete solutions to our customers.

This end-to-end approach ensures that every test solution is:

  • Digitally verified and validated prior to build
  • Engineered for safety, repeatability and robustness
  • Delivered on time and compliant with industry regulations

About AFD Systems

AFD Systems is a market-leading advanced engineering and manufacturing business, trusted by global aerospace and UK defence organisations.

With over 600 successfully completed engineering projects across 70 fixed-wing and rotary platforms, UAVs, drones and land systems, AFD delivers robust and technically-advanced solutions that drive the industry forward.

Headquartered in cutting-edge engineering facilities in North West England, AFD Systems is committed to engineering excellence, continuous improvement and a purpose to address complex challenges that contribute to a safer, more secure world.

Why choose AFD Systems?

AFD Systems acts as a seamless extension of client teams, combining advanced digital manufacturing technologies with deep engineering insight to accelerate project outcomes. Clients choose AFD Systems for:

  • Agile and efficient delivery
  • Reliable, trusted collaboration
  • High-quality, repeatable output
  • On-time, on-budget performance

our approach

Our approach is guided by a consistent set of values that ensures every project aligns with our clients’ mission goals:

  • CUSTOMER-CENTRIC | From beginning to end
  • INTEGRITY | In all that we do
  • INNOVATION | To remain in front
  • ONE TEAM | Making us stronger together

Standards and accreditations

AFD Systems is fully accredited and certified to deliver additive manufacturing solutions across a range of tightly controlled sectors. Our operations adhere to the following standards:

Related Case Studies

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“It was important for Eirtech to create an optimum design team for this high-profile project. The level of scrutiny from EASA was intensified owing to the problems that have plagued the MAX aircraft. From past experience, involving AFD from the out-set was a ‘no brainer’ for such a complex structural installation. They impressed from start to finish!”

Keith McKercher - Director of Engineering, Eirtech Aviation Services

We engaged AFD on the Human External Cargo (HEC) programme at a critical point when EASA had just begun to scrutinise our first of many STC applications for the Load Carrying System / Basket Type 1. At this time AHUK faced several technical challenges and simply put, AFD offered quick and effective support; working as a team with us to resolve some challenging technical problems, enabling confidence to be built between AHUK and EASA at panel level, and ultimately leading to a successful STC application.

Gordon Bailey - Chief Designer, AIRBUS Helicopters UK

“AFD was selected owing to their product knowledge and track record in delivering similar work to a high standard. AFD has always delivered on schedule and offer a competitive pricing model.”

Gary Wells - Chief Stress Engineer, Héroux-Devtek

Sectors

AFD Systems is known globally for its work supporting customers in the aerospace and defence sectors, while it also has in-depth expertise in highly technical and regulated sectors such as medical, motorsport, nuclear, rail and space.

In the primary sectors of aerospace and defence, we provide engineering solutions for new design, modifications, repairs and reverse engineering for major airlines, special mission platform operators, military fleets, and VIP customers.

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Aerospace
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Defence
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Space
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Nuclear
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Medical
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Rail
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Motorsport
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Trusted by organisations across the world