Challenge
An aerospace customer needed a transportable engine stand capable of supporting and aligning a ten tonne turbofan engine during build and maintenance. The stand had to pack down into a compact kit for rapid global shipment yet deliver the stiffness, strength and safety expected of permanent ground support equipment.
Flatpack construction introduced significant engineering challenges. Each component had to be light and compact enough for transport but behave as part of a rigid, high load structure once assembled. Interfaces, joints and load paths all needed to lock together precisely without requiring specialist alignment tools. The stand also had to integrate seamlessly with the customer’s existing lifting frames and handling equipment while maintaining safe operator access.
In short: design a heavy duty engine stand that could be shipped in pieces, assembled quickly on site and still perform like a permanent fixture.
How Amtek Tackled It
Amtek approached the project as a system level challenge rather than a collection of parts. We began by mapping the full load path, including how the frame would carry weight through each leg, cross member and connection point during lifting, rolling and static operations.
Engineering joints and interlocking components Because joint performance would dictate overall stiffness, we developed a series of precision interlocking features that ensured every structural member self located during assembly. These joints were designed to minimise flex, control alignment and transmit loads cleanly into the surrounding structure without requiring shims or adjustment fixtures. Joint geometry was refined through iterative modelling and analysis to ensure consistent performance even after repeated assembly cycles.
Reinforcing key load paths Using detailed stress analysis, we identified areas of high load concentration and reinforced these paths with targeted stiffening, improved material section profiles and strategic load sharing across the frame. This allowed the stand to remain lightweight for shipping while behaving as a rigid, predictable structure once assembled.
Validating stiffness and repeatability While modelling informed the early design, physical testing confirmed the stand’s behaviour under real conditions. Test assemblies were built to measure stiffness, repeatability and joint integrity, ensuring that the flatpack design achieved the same stability as a welded frame. These tests also verified that the stand could be assembled accurately without precision alignment equipment.
Designing the stand as part of a wider workflow The frame was developed to integrate with the customer’s forklift frames, lifting beams and positioning tools. Attention was given to operator access, ergonomic handling of components during assembly and compatibility with existing maintenance procedures.
The Solution and Its Impact
Amtek delivered a fully flatpack engine stand that combined transport efficiency with the performance of a permanent ground support fixture.
For the customer, the results included:
Fast global deployment The modular kit ships easily by road, air or sea and can be assembled and commissioned rapidly on site without specialist alignment tools.
Permanent fixture stiffness Reinforced load paths, precision joints and interlocking components allow the structure to behave like a welded stand once assembled, maintaining predictable alignment under full engine load.
Seamless workflow integration The stand works with existing lifting frames, beams and handling equipment, fitting naturally into the customer’s established maintenance processes.
Safer, more efficient maintenance Improved access, stable support and controlled alignment make engine build and split operations safer and easier for technicians.
Reduced downtime and simplified logistics One transportable solution now supports multiple sites, reducing the need for heavy fixed stands at every location.
The project demonstrated how Amtek blends deep engineering analysis with practical assembly considerations to create ground support systems that are strong, transportable and operationally intuitive.
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