Avlite Systems Research and Development

Manufacturing Capabilities

Avlite Systems is a world-class solar lighting systems manufacturer with a proven reputation for rapid, innovative, and agile technology solutions designed specifically for defense, government, civil and humanitarian aid operations in the most remote, toughest environments.

Avlite Systems has built a well-earned international reputation for producing the most reliable, innovative solar powered aviation lighting systems in the world earning it the preferred choice and industry’s only program of record system approval for US ARMY and DOD combat solar airfield lighting system which are currently operating in theater.

The company is a technology leader in the design and development of solar-powered aviation lighting equipment.

Part of Avlite’s business philosophy is to invest in state-of-the-art equipment to achieve superior efficiencies and the highest levels of quality control.

Keeping the manufacturing process in-house achieves better value for customers, superior quality standards and faster delivery than many of our competitors.

Avlite’s manufacturing process includes experienced electronics and software engineers, a skilled production team, cutting edge machinery and first rate QA procedures.

Some of Avlite Systems’ key capabilities include:

• 25,000sq ft purpose-built manufacturing plant
• Manufactures in excess of 30,000 navigation aids per year
• In-house SMT Electronics assembly line
• In-house rotational-moulding capabilities
• ISO9001:2000 registered
• Victorian Manufacturer of the Year
• Victorian Manufacturing Hall of Fame inductee

Design

To service the needs of our customers worldwide, Avlite Systems employs an in-house team of professional engineers who design and develop the products to exacting standards and industry requirements. Mechanical, structural and optic systems are developed from concept to completion.

The remarkable design skill of Avlite’s engineers ensures the characteristics of each product are extensively researched and, as a result, offer advanced features which greatly enhance performance and operation.

 

 

Surface Mount Technology (SMT)

Avlite’s in-house surface mount assembly line is an automated system which is used for high speed and precision placement of electronic components onto printed circuit boards (PCB). This allows Avlite to control every aspect of the construction and testing of the purpose built PCBs.

Avlite has adopted SMT as a fast and accurate way to manufacture circuit boards for high-volume aviation lighting.

As a result, our LED light drivers and microcontroller boards are built using an automated system which increases production rates, reduces labour costs and results in products with an increased level of reliability over traditional fixtures.

The extremely small size of SM components allows them to be placed on both sides of the circuit board. This has allowed us to reduce the size of the boards in the products to produce lights which are remarkably compact in size.

Circuit boards made using this technology also perform better when used in conditions where shake and vibration are a factor.

 

 

 

Electronics

After the components are loaded on the circuit board in the SMT line they then move into the ESD (electrostatic discharge) protected electronics rooms where skilled technicians calibrate, test and program the lights to customer specifications.

All boards are programmed and set using a computer controlled system. Each PCB is set according to detailed instructions to ensure that every light is manufactured to specification.

 

 

 

Photometric Testing

Of key importance in building navigational aids is the compliance to industry photometric requirements.

Avlite’s testing laboratory allows the design and evaluation of products to meet a large number of specifications throughout the world, including FAA, ICAO and CASA.

Avlite is able to quickly and accurately validate the horizontal and vertical light distribution, and peak intensity of the products to ensure they consistently meet industry standards.

 

 

Assembly

All Avlite Systems lights are assembled to exacting standards and strict guidelines.

Once the technicians complete construction of the circuit boards the production team then assemble the lights and perform a series of final inspections prior to dispatch.

Every aviation light processes through a 24 hour burn-in test, whereby proprietary software is used to cycle the lights through a series of operating conditions repeatedly over a 24 hour period. This is just one of the final inspection tests performed on every product we build.

 

Inventory

To service the often "urgent need" requirements of our customers, Avlite maintains a working inventory of finished goods.

In emergency cases, airport lighting or obstruction lighting systems can be shipped within 24hrs of order placement, for destinations around the world.

Avlite Systems also has key relations with Defence departments who have selected our systems as their expedient deployment standard. In emergency situations, options exist to draw on these resources for fast deployment around the country.

 

Rotational-moulding

Avlite System’s parent company, Sealite Pty Ltd, has over 20 years experience in building products for long term deployment in some of the harshest conditions known. The products are built to withstand extreme elements of icing, cyclonic winds, salt-spray, prolonged UV exposure and tropical humidity.

Avlite manufactures their airport cone markers on-site with state-of-the-art rotational-moulding equipment, using UV-stabilized polyethylene. In-house manufacturing allows Avlite to ensure their airport cones are robust and able to withstand the severest of conditions.

Rotational-moulding is a process used for manufacturing plastic parts of complex shapes and varying sizes. Avlite’s rotational-moulding machinists are specialists in their field and are highly skilled in this craft ensuring that every piece they produce is strong, robust and able to survive the elements for many years.

Quality Control

All Avlite Systems products are manufactured under a process that complies with ISO9001:2000 conditions for quality assurance, and continual process improvement. They are subjected to strict quality control procedures to ensure that each and every product will meet or exceed customer expectations before they are dispatched.

Throughout every stage of production each product undergoes testing & raw material batching - ensuring clear traceability through the build cycle, and minimising interruptions to our clients.

 

All Avlite Systems products are manufactured to exacting standards under strict quality control procedures. Avlite’s commitment to research and development, investing in modern equipment and advanced manufacturing procedures has made us an industry leader in solar aviation lighting.

By choosing Avlite Systems you can rest assured you have chosen the very best.

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