FAA Certification and Approval Process: An Essential Overview

Sofema Online (SOL) www.sofemaonline.com considers the key certification aspects of FAA approval

Aircraft Certification Process

The FAA’s certification and approval processes are designed to ensure the safety and reliability of the aviation industry, following a comprehensive process that includes design review, testing, inspection, and ongoing oversight.

The FAA certification of aircraft ensures that any aircraft designed, manufactured, or modified meets the safety standards before it is allowed to operate.

The FAA oversees this process, which consists of multiple steps:

Type Certification (TC):

Objective: To certify the design of an aircraft, aircraft engine, or propeller.

• Application: The manufacturer submits an application to the FAA to start the process.

• Design Evaluation: The FAA reviews the design for compliance with regulations and safety standards. This may involve technical reviews, simulations, or testing.

• Testing & Compliance: The aircraft undergoes rigorous tests (such as structural, systems, and performance testing) to demonstrate that it meets FAA safety regulations.

• Certification Issuance: If the FAA determines the design is safe, a Type Certificate (TC) is issued, permitting the aircraft model to enter service.

Production Certification:

Objective: To ensure that the aircraft, as built, conforms to the approved design and meets regulatory standards.

• Production Approval: The FAA evaluates the manufacturer’s facilities, production procedures, and quality control systems.

• Ongoing Oversight: After issuing a production certificate, the FAA continues to monitor production quality through audits and inspections.

Airworthiness Certification:

• Objective: To certify that each individual aircraft is safe for operation.

• Initial Airworthiness Certificate: After a new aircraft is built and prior to its first flight, the FAA inspects it to ensure it meets the type design and is safe to fly.

• Continued Airworthiness: Aircraft must undergo regular maintenance, inspections, and modifications to maintain airworthiness throughout their operational lives.

 Operational Certification Process

Besides certifying aircraft, the FAA also certifies the operators who will be flying, maintaining, or managing the aircraft.

Air Carrier Certification (Part 121, Part 135):

Objective: To certify airlines and charter companies that transport passengers or cargo.

• Pre-application: The operator discusses its business plan with the FAA.

• Formal Application: The operator submits detailed documentation on its operations, personnel, maintenance programs, and safety systems.

• Document Evaluation: The FAA reviews the operator’s manuals, safety management system (SMS), and procedures.

• Demonstration and Inspection: The operator must demonstrate its ability to comply with FAA regulations, and its aircraft and personnel are inspected.

• Certification Issuance: The FAA issues an operating certificate that specifies the conditions under which the operator can conduct its business.

Repair Station Certification (Part 145):

Objective: To certify maintenance organizations that perform repairs on aircraft and components.

• Application: The repair station applies to the FAA with a request for certification.

• Document Evaluation: The FAA reviews the station’s manuals, capabilities, facilities, and personnel qualifications.

• Inspection: The repair station’s equipment, processes, and quality assurance systems are inspected.

• Certification Issuance: The FAA issues a certificate if the repair station meets all regulatory requirements.

Aircraft and Equipment Approval Process

The FAA ensures that specific equipment, such as avionics, engines, and other aircraft parts, meet regulatory standards through an approval process called Technical Standard Orders (TSO). Manufacturers of components must show that their products meet minimum performance standards defined by the FAA.

TSO Approval - Objective: To approve the production of equipment and parts to be installed in aircraft.

• Application: The manufacturer submits an application along with detailed designs and specifications.

• Testing: The equipment is subjected to testing to verify compliance with FAA technical standards.

• Approval Issuance: If the FAA is satisfied, a TSO approval is granted.

Supplemental Type Certificate (STC):

Objective: To certify major modifications or changes made to an existing aircraft.

• Application: The applicant submits an application detailing the proposed modification.

• Evaluation and Testing: The FAA evaluates the modification, which may include flight tests, ground tests, and technical reviews.

• STC Issuance: The FAA issues a certificate that authorizes the modification to be applied to specific aircraft.

Safety Management and Oversight

The FAA requires a Safety Management System (SMS) for most aviation operators, repair stations, and manufacturers. An SMS integrates safety policies, risk management, safety assurance, and promotion to ensure that safety is continuously monitored and improved.

Enforcement and Continuing Oversight

Certification is not a one-time process. Once certified, operators and manufacturers are subject to continued oversight by the FAA. This includes:

• Periodic Inspections: FAA inspectors conduct regular audits and inspections of airlines, maintenance organizations, and pilots.

• Incident Investigation: Any aviation incidents or accidents are investigated by the FAA to determine causes and enforce corrective actions.

• Enforcement Actions: If non-compliance with FAA regulations is identified, the FAA can issue fines, suspend certificates, or impose other penalties.

Next Steps

Sofema Aviation Services (SAS) and Sofema Online (SOL) provides regulatory training related to Bilateral relationships between EASA – FAA – TCAA and UK CAA. Please see the websites or email [email protected].