Alp Aviation Reopens Its Doors to Sectoral Press After a Long Break
On November 30, 2023, representatives from the sectoral press, including Defence Turkey Magazine (9 press members), were welcomed at Alp Aviation's facilities in Eskişehir. The purpose was to provide firsthand information about the company's organizational structure (business units), ongoing projects, and production facilities. The visit began with a briefing made by Alp Aviation's Ankara Coordinator and ALPTEKNİK AVIATION Vice Chairman Yılmaz GÜLDOĞAN, National Programs Manager Ahmet Cihan ALBAYRAK, and Engineering and Design Director Atilla KAYA. Following the briefing, the press representatives were given a comprehensive tour of Alp Aviation's facilities, where they gained insights into ongoing activities, technologies utilized, and the company's production infrastructure.
Alp Aviation, representing around 20% of Turkish aerospace industry exports, has solidified its position as a preferred partner for major global companies and organizations in the sector. This recognition stems from its technological prowess, extensive experience, versatile capabilities, vertical integration, professional approaches, and innovative products and services, all instrumental in shaping the aerospace industry's evolution. As Sikorsky's most successful global subsidiary, Alp Aviation oversees its subsidiary, ALPTEKNİK AVIATION, which serves as Sikorsky's authorized distributor for spare parts in Türkiye and the Turkic Republics.
Operating across four modern temperature-controlled facilities covering an indoor area of 50,000 sqm in Eskişehir Organized Industrial Zone (OSB), the company houses cutting-edge resources. This includes 250 state-of-the-art multi-axis machine tools (3- and 5-axis) and advanced quality control equipment, such as solid model based CMM and GOM technologies. Alp Aviation maintains a robust industry position, equipped with over 200 specialized processes, non-destructive testing lines, and extensive test and laboratory capabilities. Many of these capabilities are both customer-approved and NADCAP approved, backed by a strong network of subcontractors, primarily composed of SMEs. The company possesses extensive experience in processing a wide array of materials, including titanium, inconel, nickel, aluminum, steel, stainless steel, copper alloys, and super alloys.
To effectively manage its growth, ALP HAVACILIK, specializing in designing and manufacturing subsystems, assemblies, and precision components for the defense and aerospace industry in a 'vertical' structure, has transitioned to a product-based organizational model from a functional one. The company now operates through four distinct business units: the Helicopter, Engine, Aerostructures, and Landing Gear units. Each unit boasts dedicated teams, encompassing operations directors, engineering managers, quality teams, engineering teams, and production planning teams.
Alp Aviation closely collaborates with TUSAŞ, TEI, Turkish Technic, ASELSAN, and TAAC, particularly on indigenous product projects within Türkiye. The company serves international export markets in the US, Canada, France, Poland, Italy, the UK, and Spain, catering to industry leaders such as Sikorsky, Lockheed Martin, Honeywell, Boeing, Collins Aerospace, Pratt & Whitney, Pratt & Whitney Canada, Safran, CESA, Mecaer, Heroux Devtek, PZL Mielec, and A. Abete SRL. Remarkably, over 90% of Alp Aviation's revenue is derived from exports.
Alp Aviation manufactures parts (including landing gear components) for rotary-wing and fixed-wing aircraft, and engines. Its products are utilized on various air platforms such as the UH-60/S-70 Black Hawk, SH-70 SeaHawk, S-76, S-92, CH-47, CH-53, T-70 TGMH, alongside our leading aerospace company TUSAŞ's indigenous GÖKBEY and KAAN aircraft. Moreover, Alp Aviation's components are integrated into aircraft including the B737, B747, B777, B787, A319/NEO, A320/NEO, A321/NEO, A330, A340, A350, and A380. Nearly every commercial aircraft and/or its engine in operation features an Alp Aviation product.
Alp Aviation has made a substantial investment in cutting-edge machine tools as part of the Turkish General Purpose Helicopter Program (TGMHP), aiming to establish itself as a center of excellence for rotary wing aircraft components in Turkey. The total investment, which encompasses facilities and machine parts, has reached approximately USD 90 million. Alp Aviation serves as the exclusive supplier for a range of crucial components utilized in the production of T-70 Black Hawk Helicopters under TGMHP. This includes all gears, gearboxes, primary flight-critical and dynamic elements like propeller shaft housing and main shaft, along with tail rotor drive shafts (TRDS), their assembly groups, flight control mechanisms, and landing gear. Moreover, Alp Aviation ensures the provision of spare parts for each critical rotary component it delivers. Black Hawk Helicopters worldwide use the TRDSs produced by Alp Aviation, the sole source global manufacturer of this critical component.
Within the scope of the program, a Gearbox (Transmission) Test Center was also established in 2017.
Alp Aviation aims to take part in various indigenous helicopter projects of TUSAŞ, including T625 GÖKBEY, T629 ATAK 1.5, T929 ASTH, and T925 10 Ton Utility Helicopter, leveraging the production infrastructure and expertise (production of helicopter gears and magnesium gearbox housings for the first time in Türkiye, Flight Control System detail product designs, gearbox integration, and test technologies) gained under the TGMHP program.
Alp Aviation holds the distinction of being the first company globally, aside from Sikorsky, to produce the main transmission (Quick Change Assembly) for the Black Hawk Helicopter within the T-70 TGMHP program.
Alp Aviation has the capability to produce gearbox housings using both aluminum and magnesium “housing” technology based on customer preference.
Alp Aviation acquired Magnesium Housing production technology as part of TGMHP. Prior to delivery, every main transmission/gearbox manufactured for Black Hawk Helicopters undergoes a rigorous 45-minute test at the Gearbox Test Center, simulating helicopter conditions.
Alp Aviation aims to leverage the know-how and production infrastructure it has gained so far in Türkiye's domestic and national programs.
One of the areas in which Alp Aviation specializes is landing gear. The company exports these specialized products through OEM partners such as Collins Aerospace and Safran. While directly providing landing gear for the T-70 TGMHP program to TUSAŞ, Alp Aviation also supplies Sikorsky with landing gear to meet the demands of global users. Despite the current hold on deliveries within Türkiye for the 38th T-70 Helicopter, the company continues to supply parts and subsystems to Sikorsky for worldwide users.
Another indigenous design project for aircraft undertaken by Alp Aviation involved the complete process from design and development to testing and production of the Accessory Gear Box. This flight-critical component was specifically designed for the TS1400 Turboshaft Engine, which was developed domestically by TEI. Alp Aviation was commissioned by TEI to deliver the Accessory Gear Box for use in TS1400 Engines.
In October 2021, Alp Aviation delivered its first Accessory Gear Box to TEI. Before delivery, this Gear Box underwent rigorous testing at Alp Aviation facilities, ensuring its performance under specific conditions. Following delivery, it was subjected to successful year-long testing on the TS1400 Core Engine. Subsequently, integration efforts began on the T625 GÖKBEY Helicopter. During the maiden flight of the GÖKBEY Helicopter powered by the indigenous TS1400 Turboshaft Engines in April, Alp Aviation's Accessory Gear Boxes were utilized on both engines.
Alp Aviation, placing significant emphasis on domestic and national programs, aims to bolster collaborations with industry leaders such as TAI, TEI, and ASELSAN, each renowned in their respective fields, leveraging its full spectrum of capabilities, in the upcoming period. The utilization of Alp Aviation's products and services in domestic and national air platforms and engines remains a source of pride for both the company and its employees.
Alp Aviation actively implements "Industry 4.0" technologies within its Business Units to elevate production efficiency and productivity. During the facility tour, we witnessed the practical application of robotic arms and autonomous vehicles. All processes, including tool loading and part cutter loading, are performed using robotic arms and autonomous vehicles. Currently, there are nine fully automated robotic arms overseen by a single operator, and two autonomous vehicles—one charges its battery while the other performs tasks. Augmented Reality is also integrated into the Business Units to ensure accurate assembly, preventing potential operator errors when assembling parts or units with similar appearances. Alp Aviation's first facility, the Aerostructures Business Center, is currently undergoing a comprehensive renovation, encompassing a complete redesign of both its infrastructure and superstructure. Renamed “Future ALP,” the updated center is being transformed into a fully automated production line, adopting the “Dark Factory” concept for lights-out production. The renovated facility is anticipated to be operational by late 2024 or early 2025. Meanwhile, the Helicopter Business Center has initiated the first pilot implementation of “Industry 4.0” technology, employing software developed by Alp Aviation engineers
