Embodying aerospace excellence, CAV Systems’ innovative IPS technologies ensure that nobody is frozen in flight
Boasting a distinguished legacy spanning over 83 years, CAV Systems (CAV) is a true leader in the development of ice protection and drag reduction systems within the aerospace sector. Founded in 1942 under the name of TKS®, CAV was initially incorporated between Tecalemit, Kilfrost, and Sheepbridge Stokes when the UK Government’s Ministry of War required a solution to tackle icing on newly-designed RAF Command aircraft – and the rest is history.
Since then, the company has partnered with a plethora of renowned aerospace manufacturers and OEMs, engineering specialist ice protection systems for critical flight applications, establishing a vast global presence and impressive reputation along the way. Operating its headquarters in Consett, County Durham, with an additional location in New Century, Kansas, CAV continues to be the leading supplier of laser-perforated surfaces and the only supplier of fluid-based ice protection systems across the globe. Manufacturing Today sits down with Ian Jackson, Managing Director at CAV, and Phil Hopkins, Vice President of Business Development, to learn more about how CAV’s innovations continue to revolutionize ice protection processes in the aerospace sector.
“CAV Systems has been in business for over 80 years, predominately designing, manufacturing and engineering ice protection systems for the aviation industry, mainly within propeller-based aircraft,” Ian begins, offering an introduction to CAV’s capabilities. “We work with a diverse range of customers and businesses, primarily in the civil sector, with some involvement in military projects. We’ve been in our current location in Durham for over 40 years and have a very local workforce of around 110 people.
“The product that we offer is the result of innovative engineering, involving the micro-perforation of metallics and carbon fibers. Lots of small holes are drilled into titanium – around 800 holes per square inch – which we then form into the leading edge of a wing. We then do some chemical engineering to control the flow of fluid coming out of the panels, which we then assemble into an ice protection kit.”
With a comprehensive scope of design, manufacturing and engineering capabilities, CAV is more than a solutions provider: it is a true partner of choice across all corners of the global aerospace industry. From initial design conception to the testing, development, manufacture, and integration of its systems, CAV champions client collaboration at every stage to provide cutting-edge solutions that are engineered and tailored to every aircraft and need.
Two of CAVs most notable systems are its TKS® and SLD products. Its TKS® system is renowned as the industry’s highest-performing in-flight protection system. The system is certified for installation in over 100 different aircraft model variants, and also available for integration on a wide range of general aviation aircraft and unmanned aerial vehicle models in factory or as retrofit, providing both incredible efficiency and versatility. The system offers both anti-icing and de-icing capabilities, using a chemical fluid to break down ice on the aircraft’s wings, windshield, propellers, stabilizers, and fixed landing gears. CAV’s SLD Guard system works in a very similar way; specially designed to address the changing FAA certification regulations, it works to remove and prevent ice build-up from SLD icing caused by precipitation, making it preferable for Flight Into Known Icing (FIKI).
“We always try to infiltrate the end users and manufacturers as early in the design stage as possible. This allows our system to be seamlessly integrated into the aircraft design rather than added as a separate component at a later date. This approach significantly reduces costs for both us and the manufacturer. Furthermore, at present, competitors of de-icing solutions do not offer the capabilities we provide,” Phil explains.
“Every system is unique; we’re constantly monitoring the sector for new aircraft and we have the industry knowledge to identify and solve problems for our customers. Ice protection makes up around 80 percent of what we do, but we can offer so much more to our customers,” Ian continues. “We’re seeing a lot of interest in new start-ups in the eVTOL market, for instance, where aircraft manufacturers are required to consider how their vehicles will cope when they encounter ice in flight.
“Anti-ice is our core product, and it can be applied to these electric aircraft. Our anti-ice system is certified by the FAA and the CA so that, if you see ice on your flight path, you can switch on our system and prepare your surfaces before the encounter; the fluid coming through the system will prevent ice from forming.”
The eVTOL and hybrid markets are growing rapidly as the world seeks more sustainable travel solutions; the aerospace sector is no different. As a company that personifies innovation at its core, CAV is determined to support manufacturers in the electrification of their aircraft, adapting to the increased market demand to build solutions fit for the future.
“We’re trying to grow our presence within the eVTOL sector. Our goal is to introduce ourselves to as many of the new manufacturers in this area as possible, understanding and working with as many as we can,” Phil reveals. “It’s key for us to diversify and be involved with these projects because these aircraft are, potentially, the future of flying, and it’s important for CAV to be a part of that in its interim. We need to understand how these new aircraft are being designed and how we can apply our technologies and capabilities to these projects.”
Ian adds: “People assume that eVTOLs will use electricity for every function, but our ice protection systems are very low energy as they’re fluid based.”
From evolving customer demands and rising expectations to broader economic developments, the market is poised for continued transformation. Building upon its past successes, CAV is well-positioned to continue to grow and prosper, accelerating its support for its clients to new heights. With its sights set on expanding its horizons, it’s evident that innovation and safety will always remain at the core of CAV, no matter what the market brings and what its customers require.
“My role within CAV Systems is to grow the business. Over the coming years, we hope to grow exponentially in terms of our portfolio, our annual turnover and the scope of manufacturers that we work with. We’d like to expand significantly into new sectors over the next five years, particularly into eVTOLs, drones, and UAVs, as we’re known throughout the industry for our ice protection systems, but a lot of people aren’t aware of our other capabilities,” Phil finishes. “Our goal is to be known for the whole portfolio of technologies that we offer.”