Card Creation and Approval - Flight Card Planning and Test Execution Flow

Aug 30, 2026

Flight test card creation and approval workflow for an aerospace manufacturer, detailing standard planning and reference documents, structural placards, and flight card content structure. It specifies how a matrix is derived from an expanded pilot checklist, how cockpit switch positions are mapped to takeoff/climb/cruise/approach/landing regimes, and how deviations and special configurations are highlighted for last-second checks. A process flow then guides final card assembly, preflight meeting confirmation, test pilot categorization, and multi-party sign-off, culminating in a complete example matrix run and landing performance procedure.

LanguageEnglish

CategoryForms

FormatDOCX

Pages5

Reading Time2 min

AccessFree to download

Flight Card Content

System Configuration and Cockpit Switch Setup

Matrix Development and Regime Deviations

Normal vs Exceptions with Emphasized Systems

Standard Test Planning/Reference Documents

FTE Handbook and Aero/Thrust/S&C Data

Structural Placards and Known Limitations

Card Assembly and Approval Process

Preliminary Test Card and Engineering Discussions

Final Deck Assembly and Configuration Review

Preflight Meeting and Agreed Changes

Sign-off by Test Conductor and Leadership

Example: Landing Performance Test Card

Test Purpose and Conditions

Procedure and Target Values

Card Creation and Approval A Southern California airframe manufacturer provides the outline below to create test cards: STANDARD TEST PLANNING/REFERENCE DOCUMENTS * "FTE" HANDBOOK ESTIMATED AERO PERF & S&C DATA -- P.E. CURVES; AOA & BETA INDICATEDVSTRUE THRUST SETTINGS SYSTEMS "LIMITATIONS" KNOWN USEFUL INFO: RUNWAYS, A/C DIMENSIONS/DWGS, ETC * STRUCTURAL PLACARDS PREPARED BY STRUCTURAL DESIGN GROUP DISTILLATION OF STRUCTURAL DESIGN CRITERIA PLUS DATA/CURVES HISTORICALLY KNOWN TO BE NEEDED --OPERATION OUTSIDE "AFM" WEIGHTS & CG'S -- FLOOR LOADINGS FOR BALLAST -- ABNORMAL FUEL USAGE FOR CG CONTROL -- LIMIT LOADS OF S/G'D PARTS 0 FLIGHT CARD CONTENT * FLIGHT CARDS CONTAIN A SECTION TITLED "SYSTEM CONFIGURATION" WHICH DETAILS THE SETUP OF AIRPLANE SYSTEMS RELEVANT TO THE TEST CARD THIS GENERALLY MEANS CALLING OUT THE REQUIRED POSITION OF COCKPIT SWITCHES. * A MATRIX IS DEVELOPED FROM THE PILOT'S EXPANDED CHECKLIST, & REVIEW OF SPECIAL TEST SYSTEMS. TAKEOFF, CLIMB (BEGINNING AFTER GEAR, FLAP & SLAT RETRACTION), CRUISE (ABOVE FL180), APPROACH (BEGINNING BELOW FL180 & PRIOR TO GEAR DOWN, FLAP OR SLAT EXTENSION), LANDING (BEGINNING AFTER GEAR DOWN & LANDING FLAPS SELECTED). ALL COCKPIT SWITCH POSITIONS ARE LISTED FOR TAKEOFF --IF/WHEN THEY ARE CHANGED FOR EACH REGIME THAT IS NOTED. -- "BOXED" ITEMS ARE FLIGHT TEST UNIQUE SYSTEM SWITCHES. -- BASIC CONTROL LEVERS/CONTROLS ARE NOT LISTED (I.E., WHEEL, FLAP/SLAT, LANDING GEAR, THROTTLES). * FLIGHT CARDS STATE "NORMAL FOR TAKEOFF, CLIMB, ETC. EXCEPT" & THEN LIST DEVIATIONS FROM THE MATRIX FOR TAKEOFF, ETC. AS APPROPRIATE TO THE TEST * TEST REQUIREMENTS ARE OFTEN DIFFERENT THAN THE MATRIX "NORMAL" CONFIGURATION. * WHERE TEST RESULTS ARE HIGHLY DEPENDENT ON CERTAIN SYSTEM CONFIGURATIONS THE FLIGHT CARD STATES "NORMAL FOR TAKEOFF, CLIMB, ETC. WITH" & THEN LISTS ITEMS IN THE MATRIX TO EMPHASIZE THEIR IMPORTANCE & PROVIDE A LAST SECOND COCKPIT CHECKLIST. A flowchart summary looks like: -Prepare Preliminary Test Card -Discussion with R & A Engineer -OHA -IFRs/ADRs -Discussion with P.I.C. -Structural Placards Document -FTE Handbook -Test Planning Meetings | | - Test Conductors Finalize Individual Cards | | - Test Conductors:Assemble Individual Cards into Deck for Each Flight and Review Test Aircraft Configuration Report/Records for Impact on Tests | | - Preflight Meeting Chaired by Test Coordinator and Conducted Per Checklist | | -Test Conductor Makes Agreed To Changes During Meeting | | - Chief Experimental Test Pilot assigns OHA Category tests | | - Approval signed by Test Conductor, Test Coordinator, P.I.C. and Chief Experimental Test Pilot (or designee) An example of this company's test card is shown below: MATRIX RUN #_______ TEST RUN________ CARD __________ TEST: LANDING PERFORMANCE AIR/GND DISTANCE: MMEL CASE: 1 HYD SYS INOP IN ONE WHEEL INOP TEST NO. 04510.00, 04520.09 FUSELAGE NO.________ FLIGHT NO.________ TEST REFERENCE: FAR 25.125c, 25.1309, TEST PURPOSE: Demonstrate landing air/ground distance performance with 6002 brakes, 306 A/S & 3 wheel speed transducers for the MMEL case of 1 HYD SYS INOP IN ONE WHEEL INOP. TEST CONDITIONS SYSTEM CONFIGURATION NORMAL FOR LANDING WITH : ALTITUDE : APPR A/P : ON/OFF ANTISKID:ARM AIRSPEED : 1.3VS ATS : ON/:F APS : DISARM FLAP/SLAT: /LND # WHEELLH / RH SPOILERS : ARMED THRUST : NOTED (3 o FPA) BRAKE SYS INOP CAPT A/S : PROD LDG GEAR : DN WEIGHT/CG: HVY/FWD LIM HVY = WT < MLW/FWD LIM = 7.5 to5.1%+0.50.0% INSTRUMENTATION DATA RATE: 400 SPS OTHER: WIND KIT, RADIO CAR, PHOTO, FANS NOTE: 3 GOOD RUNS REQUIRED @ EACH LANDING FLAP > 6 RUNS TOTAL PROCEDURE 1.During final approach: Confirm Arresting Gear Removed (a) Verify brake temps are less than ______ (b) Complete FUEL/WEIGHT log entry (c) Verify FTDS sample rate > set 2. Conduct a stabilized approach and landing at the following target values; EPR:______ V/S:_____ FT/SEC / ______FT/MIN 1.3VS(+/2): ____ KTS THROTTLE RET

FAQs

What key standard documents are used to prepare test cards?

Preparation relies on an FTE handbook, estimated aero perf and S&C data (including P.E. curves and thrust settings), systems limitations, and known useful information such as runways and aircraft dimensions. It also includes structural placards and criteria data historically needed for special cases.

How is the flight card matrix created and applied to test regimes?

A matrix is developed from the pilot’s expanded checklist and a review of special test systems, then applied across takeoff, climb, cruise, approach, and landing. Cockpit switch positions are listed for takeoff and adjusted when they change for each noted regime, while basic controls are not listed.

How do flight cards handle configuration deviations and special system emphasis?

Flight cards state a normal configuration for each regime and then list deviations from the matrix as appropriate to the test. When certain system configurations strongly affect results, the card specifies “normal … with” and emphasizes the matrix items to support a last-second cockpit checklist.

Who approves the finalized flight cards and what happens during the preflight meeting?

Approval is signed by the test conductor, test coordinator, P.I.C., and chief experimental test pilot (or designee). A preflight meeting chaired by the test coordinator confirms the checklist, and the test conductor agrees to changes during the meeting before the test is conducted.

Aug 30, 2026

Upload by Emma Wilson