Sikorsky has received FAA certification to offer a one-time life extension for specific main gear box housings on its S-92 helicopters. By leveraging the health and usage monitoring systems (HUMS) data collected from Sikorsky's S-92 fleet, representing more than 300 aircraft and 2.3 million fleet flight hours, the company has developed a methodology to more accurately determine the life-limit for parts and help alleviate supply chain issues affecting the industry.

This earned credit is based upon examination of the HUMS data for individual housings, allowing continued operation beyond the current 4,300 hour limit. This extension is made possible by utilising Sikorsky's revolutionary LifePlus methodology, which determines remaining component life of S-92 helicopter parts based on actual aircraft usage. The certification will allow operators to keep gearboxes in service for more hours, mitigating downtime and increasing operational readiness and availability for the fleet. LifePlus will continue as a multi-phase intelligent approach to component life calculations with current FAA certifications planned in 2025 and beyond.

“The FAA certification of the main gear box housing earned life credit is just one of the many examples of Sikorsky's continued investment in the S-92 platform,” says Leon Silva, vice president of global commercial and military systems. “For over a decade we have been investing in LifePlus, and we are thrilled to see it becoming a game changer for the industry.”

In late 2023, the FAA approved the first component life extension using LifePlus technology on the S-92’s main rotor hub, raising the retirement time from 9,000 hours to 15,000 hours, or 45,000 ground-air-ground cycles, extending the life of current parts in the fleet.

With LifePlus, Sikorsky is redefining the way the industry thinks about component life and maintenance, providing operators with the support they need to keep their helicopters in service for longer, while also improving safety and reliability.