Constant Aviation has completed its 17th 7,500-cycle inspection of the Bombardier Challenger 300, more than any other MRO in the world. With nearly 800 Challenger 300 series aircraft having been delivered worldwide since 2004, making it the world's top-selling super midsized aircraft, many units are reaching 7,500 flight cycles. Constant's experience makes it the only MRO capable of performing this comprehensive inspection and maintenance process with maximum efficiency and minimum aircraft downtime.

“There have been fewer than 20 7,500-cycle inspections completed worldwide to date, so, with 17 of them performed by us, our experience and expertise are unmatched,” says CEO David Davies. “With every inspection, we have gained knowledge and found ways to make the process more efficient. As more Challenger 300s come due for this inspection and maintenance process, we are in the best position to do the work and return aircraft to service with as little downtime as possible.”

The extensive Challenger 300 7,500-cycle inspection requires more than 8,000 man hours to complete. Specially-trained technicians at Constant's full service facilities in Cleveland, Ohio, and Orlando, Florida, remove the aircraft's horizontal stabiliser, engines, interior, APU, windshields, landing gear, flaps, winglets, baggage door, panels and many other components. Some are removed to be tested, while others are removed to provide the technicians with access to specific areas of the aircraft.

Once disassembled, the airframe and components are inspected for corrosion, cracks or other defects. Non-destructive testing is done in-house by Constant Aviation's team to streamline the inspection process. For components that are most susceptible to wear and corrosion, such as inlets, landing gear, thrust reverser doors, interior finishes and avionics, Constant Aviation engineers and designers are on hand to offer long-lasting overhaul and repair solutions.

Before each aircraft is returned to service, further inspections are conducted during reassembly. The entire 7,500-cycle inspection process can take two to three months to complete, although productivity improvements made possible by Constant Aviation's experience with the process are making it more efficient.

“If you operate an early-model Challenger 300, now is the time to start planning for this inspection,” continues Davies. “There are nearly 800 Challenger 300 series aircraft flying today, and we are the aviation industry's go-to resource for the completing the 7,500-cycle inspection and maintenance process expeditiously and with maximum focus on safety.”