Autopilot developer Merlin has completed the design and build of a certification system bench, built to the fidelity required for certification testing, at its Boston, Massachusetts headquarters.

The certification system bench is a flight test simulator with both certifiable software and hardware components that allows Merlin to constantly test its advanced automation systems. Unlike traditional in-flight testing, the certification system bench can be utilised irrespective of weather, maintenance schedules and pilot availability. Furthermore, it features cameras that provide remote accessibility and testing abilities for Merlin's distributed, global team, and includes three screens that represent the pilot deck as well as accurate instrument panels and primary flight displays.

"In many ways, the certification system bench acts as a testing 'funnel'. It allows us to test hundreds of cases with speed and ease, selecting edge cases to take to in-flight testing. As a result, we're able to reduce the use of our test aircraft and keep it for limited cases only," says Sherif Ali, chief engineer for the certified Merlin Pilot project. "With pilots on the certification system bench, we are able to learn multitudes about human factors while gaining accreditation towards our STC. This was a material investment for the company, which is wise. No other company in the sector has put more resources towards this type of testing simulator, but we see it as critical in order to exceed our certification timeline targets."

The certification system bench represents a significant investment for Merlin as it provides a true, one-to-one replica of the company's in-flight technology. Equipped with the same software and hardware components, it supports Merlin's methodical developmental approach by enabling greater precision and speed, and ultimately expedites the path towards STC as ground tests on the certification system bench are accredited by regulatory authorities. It also allows for greater accessibility and routine testing for Merlin's global team, alleviating test flight inhibitors such as weather and aircraft maintenance, which can increase as the pace of testing accelerates.

"Ensuring the Merlin Pilot is robust, safe and reliable is our top priority, which underscores this system bench build as a huge milestone in our certification journey. It took the team six months to design, vet solutions for and build the certification system bench to extremely stringent specifications," says CEO and founder Matt George. "While the simulator costs millions of dollars more than our actual aircraft, it can run continuously and without constraints to collect data that rapidly accelerates our certification programme."