Fetters AeroSpace
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Before You Can Build Helicopters, You Got To Build A  Factory!

          The following information demonstrates our experience to build a rotorcraft company from the ground up. We know how to build a facility that can produce rotorcraft, because we have done it before, using our knowhow to save you time and money by avoiding the unavoidable costly mistakes if you attempt to do so on your own. The factory below had a total of 52 personnel consisting of the manufacturing staff, office staff, design staff and sales staff to cover the world, and this provided us with the capability to build and ship 6 helicopters a week!

          After shipping over 500 helicopters, Mr. Fetters decided to close the factory in the year 2000 and sold limited manufacturing rights to a Chinese based company. Afterwards, Mr. Fetters was then free to pursue other goals in the newly developing UAV industry.


Revolution Helicopter Corp., Inc.

PictureThe 22,000 sq/ft. Manufacturing facility in Excelsior Springs Missouri was an inspiration and never disappointed our visitors.
          Revolution Helicopter Corp., Inc. (RHCI), was founded in 1990 to design and manufacture affordable helicopter kits. As a result, this rapidly growing technology firm has set new standards for not only the kitplane industry, but for all light helicopters in general. RHCI's mission is to utilize innovative technology to develop, build, and market highly advanced helicopters which meet a wide variety of consumer needs, RHCI's key strengths stem from its state-of-the-art advances in helicopter production and design, competent core management, strong customer service, innovative marketing programs coupled with ongoing product development and continuous quality improvement engineering. RHCI's corporate headquarters is housed in a 22,000 plus sq. ft. facility, adjacent to its own private helipad, within the city limits of Excelsior Springs, Missouri - a historic community fewer than twenty miles from downtown Kansas City.

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The Revolution Helicopter showroom was open to the public by three sides with full-view windows, showing off their helicopters to the pubic as they drove by on the main road into the city.
          Revolution Helicopter Corp., Inc. (RHCI), was founded in 1990 to design and manufacture affordable helicopter kits. As a result, this rapidly growing technology firm has set new standards for not only the kitplane industry, but for all light helicopters in general. RHCI's mission is to utilize innovative technology to develop, build, and market highly advanced helicopters which meet a wide variety of consumer needs, RHCI's key strengths stem from its state-of-the-art advances in helicopter production and design, competent core management, strong customer service, innovative marketing programs coupled with ongoing product development and continuous quality improvement engineering.

          RHCI's corporate headquarters is housed in a 22,000 plus sq. ft. facility, adjacent to its own private helipad, within the city limits of Excelsior Springs, Missouri - a historic community fewer than twenty miles from downtown Kansas City. RHCI moved to its present location in 1993. Over the years, the headquarters has undergone significant changes to adapt to our manufacturing requirements. Extensive remodeling and the installation of a sophisticated computer network tied into a dedicated high speed ISDN line, ensures instantaneous interdepartmental communications and responsive links to external data resources like the internet, dealer and international distributor e-mail servers, etc.

          The facility is segmented into separate administrative, manufacturing, storage, shipping and receiving areas. Executive, sales and administrative offices, including an expansive glass showroom, waiting and reception areas, Engineering/R&D department and boardroom occupy the front of the building. All manufacturing departments are arranged to facilitate production throughout and optimize inventory accessibility.
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Customer Support

          Excellence in Customer Support is measured in four ways: experience, capability, commitment and knowledge. RHCT has earned a reputation of excellence and consistently receives high marks in meeting and exceeding customer expectations.

          Our Customer Service Department is charged with ensuring complete client satisfaction, along with providing technical support to customers across the globe. This department monitors the delivery, warranty and any potential repairs an owner may require.

          Technical support is provided by a team of dedicated engineers and helicopter pilots familiar with all aspects of our products. Their goal is to provide rapid response to customer inquiries. The team has total access to all RHC design and engineering resources to facilitate investigation of potential problems and quickly implement and execute the proper course of corrective action.

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Technical Support

          A technical support committee composed of key RHC managers meets at regular intervals to review customer service requirements, recommends improvements or updates to RHC products and scrutinizes aircraft performance characteristics. RHCI is also fully equipped to perform repairs and modifications for each manufactured component. RHCI designs and develops any equipment and special tooling required to maintain, repair and overhaul our products.

          RHCI is also fully equipped to perform repairs and modifications for each manufactured component. RHCI designs and develops any equipment and special tooling required to maintain, repair and overhaul our products.

          Our dedicated customer service department answers customer’s inquiries, requests, and other needs. Timely and accurate response to the customer is the hallmark of RHCI's support organization.

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Quality Control

          Quality is not something that is taken for granted. Every single day, the company strives to make sure its products deserve the RHCI name. Quality is everyone's job, but the Quality Control Department insures that each part meets exacting standards.

          Team members play a vital role in an ongoing program of continuous quality improvement by performing statistical checks and confirming that all specifications and requirements are being met, or exceeded.


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Training & Education

          Whenever possible qualified applicants are recruited from within the area, and trained for a rewarding career in aircraft manufacturing. This is not only beneficial for the employees, but for the community as well. RHC has developed an ongoing education program for its employees where inter-departmental cross-training plays a vital role in their development.

          All employees are given orientation classes regarding the company, personal safety, and the critical nature of the products they are manufacturing. In depth indoctrination to a specific manufacturing process follows, and recurrent training program keeps RHCI personnel in tune with the latest production techniques and materials.

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Community Service & Interaction

          RHCI is dedicated to supporting the surrounding community, RHCI's positive economic impact is reflected in job creation and investment in the local economy. The company consistently volunteers aircraft and personnel for community service work, including missing person searches, fugitive tracking and drug eradication. These services save the community thousands of dollars by accomplishing, in hours, what would ultimately take the police and fire departments weeks to achieve. Additionally, RHCI makes its facilities available to schools and civic groups for tours, and also takes an active part in promoting general aviation at parades, sporting events and airshows.

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RHCI staff members were awarded certificates in appreciation for assisting the local police department.
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RHCI offers tours of its manufacturing facilities to local schools, as well as, customers.

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Research & Development

          Every component manufactured by RHCI is the result of an intensive research and development effort. Teams of engineers and aerodynamic design experts continuously work at improving existing products, as well as, developing new ones.

          RHCI is constantly moving ahead, changing and improving the way it makes its aircraft in order to stay competitive in today's global marketplace. As the undisputed leader in the helicopter industry, our goal is to constantly move our products and services into the next generation of quality and performance. Input and suggestions from existing customers influence the course of the development efforts and often lead to innovative approaches to traditional helicopter design and engineering issues. RHCI values customer input and listens when they express their opinions. By striving to meet the ongoing needs of customers, RHCI believes that it has an advantage over all other aircraft manufacturers. RHCI’s philosophy is to listen and respond.


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Service Bulletins

          RHCI has developed a system of distributing Service Bulletins to current owners and operators regarding potential operational, maintenance and safety issues. To assure the timeliness of these memoranda, particularly pertaining to safety matters, all ownership transfers of any RHCI aircraft are tracked.

          RHCI strives to ensure that all documentations and publications are upto-date and reflect the latest assembly, operational and maintenance procedures. All information is reviewed on a periodic basis and rewritten, as needed, to reflect those changes and improvements which are part of the RHCI continuous quality improvement program.

          These informational updates are available on a timely basis to provide our customers with valuable information needed to make informed decisions concerning service and maintenance of their aircraft.

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Warranty

          Exacting standard of quality are built into each and every product RHCI produces. We offer a standard 90-days warranty that covers parts against defects in material and workmanship, plus any non-conformance to design and manufacturing specifications. At RHCI, customers are assured of receiving the best quality products and services. We back what we build!

Sales and Service Centers

          RHCI has established a worldwide network of Sales and Service Centers (SSC), along with a dealer and distributor network, to meet customers' needs and expectations. The SSCs' objective is to provide customers with the best service in a timely manner.

          SSC representatives are trained in all aspects of our products, and have the information and tools necessary to facilitate any inspection, maintenance or servicing requirements a customer might have; including, builder assistance, pre-first flight final inspection, tracking and balancing and flight instruction.

          RHCI's system of SSCs provides experienced personnel with the technological knowledge needed to meet the needs of customers. All SSCs are subject to extensive, periodic audits by RHCI to ensure adherence to the highest quality standards. RHCI is continuously working to improve and enhance its products, as well as, develop and test new ideas to meet customers' needs for the future.


Production

          RHCI has developed its manufacturing systems using a combination of traditional practices combined with innovative techniques. We have integrated advanced component technology and state-of-the-art production procedures with the high work ethic standards of a small community. The results have been outstanding.

          Flexible manufacturing processes combined with an efficient work flow and a high degree of employee involvement, facilitates an effective change when an area of improvement is identified.

          Our integrated production procedures employ a tightly scheduled flow of materials and components. This virtually eliminates inventory storage issues and allows for easy, "Just-In-Time' (JIT) material management.

          Teamwork and personal development are encouraged among RHCI's dedicated employees who are challenged to go beyond their limitations and take advantage of opportunities for individual growth, training, and the development of leadership skills. RHCI fosters a spirit of creativity wherein technological skills can be developed and refined. This philosophy, coupled with a company commitment to principles of honesty and ethical integrity, promotes ongoing dedication to continuous improvements in operations and management.

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Metal Bonding

          Bonding has replaced riveting in many areas of aircraft production. Engineered adhesives are more accurate, less labor intensive and reduce the weight of the aircraft. Metal bonding is an example of RHCI's forward thinking.

          The Metal Bonding Department fabricates tail rotor blades, clutch shoes and pads in-house, in an environmentally controlled, ultra-clean lab, Precision techniques, including the proper preparation of mating surfaces, application of adhesive film, special clamping jigs requiring precise torque and controlled curing ovens result in superior component output.






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Thermal Molding/Plastic Department

          With the latest technology in thermoplastic vacuum production, RHCI builds all plastic components in an electronically monitored manufacturing oven. Parts are fabricated using precision tooling, allowing for minimal trimming and exact fitting.

          RHCI's forming machines allow the company to fabricate its own optics, which are made of clear Lexan. These machines are used for both cockpit windshields and doors to ensure that parts are optically accurate and blemish free. Quality control is critical.

          Components are heated and vacuum formed with a thermal forming machine to provide exact precision parts and shapes, RHCI has developed revolutionary techniques to enable the mass production of complex shapes precisely and instantly.


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Machine Shop

          RHCI joins a handful of other aircraft manufacturers in having one of the most modern and complete machine shops in the Midwest.

          With a series of digitally controlled vertical mills, lathes and a peening/media blasting booth, machinists can create prototype parts, manufacture production tooling and mass produce components to within .0005 inches accuracy. Our Quality Assurance protocols guarantee consistent dimensional tolerances and materials integrity.

          Skilled machinists undergo regular training, with emphasis on the latest developments in manufacturing, tooling techniques and safety.

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Welding Department

          RHCI TIG welds every frame in precision fixtures, guaranteeing 99.9% repeatability in the production of parts and components.

          RHCI has the equipment and personnel to weld with TIG, MIG or Acetylene Gas, which gives RHCI the ability to build not only the parts required for aircraft production, but also to produce the required tooling for most of the manufacturing processes that are employed.

          Each of our welders operates within a self-contained, ventilated and lighted booth, guaranteeing precise atmospheric control of the welding environment.

          All welded parts are shot peened for stress relief, ensuring hundreds of hours of use in the field without the danger of metal fatigue.

          Immediately following this process, parts are either painted, nickel plated, hard nickel plated or anodized to protect against environmental degradation.

          The variety of welding equipment coupled with our technicians' expertise, enable RHCI to make modifications and fabricate prototype parts.

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Assembly Department

          Only highly trained employees and FAA Certified Mechanics make up our Assembly Department. They are ultimately responsible for production maintenance standards in our complex components and the completion of in-house quality tracking documentation.

          Unique in the user-built industry, RHCI pre-assembles all critical complex components like the main transmission, tail rotor gearbox, Sprague clutch, centrifugal clutch and rotorhead cones to exacting tolerances.

The gear lash is preset and bearings are stacked to establish proper pre-load; two things that are critical to safe flight and achieving TBO (Time Between Overhaul). Assembly of these components requires a high degree of knowledge, skill and experience, as well as, specialized tools and calibration equipment to assure the reliable performance of our products.


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Composite Department

          RHCI uses the latest in composite technology with pre-impregnated resin fiberglass (pre-peg) to ensure the structural integrity and longevity of the composite parts.

         The Composite Department was developed to produce parts, plugs and molds of the highest quality. The entire production group is environmentally segregated from the rest of the factory in a custom designed "clean room" and has the capacity to increase the amount of parts produced "on demand." This coincides with RHCI's commitment to JIT management, which accommodate seasonal increases in aircraft demand.

          RHCI has developed some of the most innovative pre-peg composite construction processes in the industry. Composite parts are manufactured using advanced construction techniques and "space-age" materials to provide strong and durable components.

          Specialized storage and in-house freezers make it possible to warehouse materials and supplies that are used in composite part production, protecting RHCI from intermittent supplier shortages.

          Pre-peg parts are manufactured using sophisticated bagging and vacuum techniques. The components are cured in a computer-controlled oven to obtain the strongest possible resin-to-cloth ratio for maximum strength, Molds are designed and built to operate at 250+ degrees.
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          Molds, on large mobile metal carts, are bagged and hooked to an array of manifolds and vacuum lines going to a central vacuum system. These carts are then rolled into the computer-controlled oven which raises the temperature at a specific rate, allowing the parts to uniformly fuse in the molds into extremely light, yet durable, components.
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          Composite parts are placed into special drilling and scribing fixtures, then marked precisely to facilitate the alignment process of the components to each other.
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Composite Tooling

          RHCI not only has the capabilities to manufacture its own composite parts, but the ability to produce most tooling surfaces for its tooling and molding operations. This gives us complete in-house capabilities for any type of surface coating, including preparation for metal bonding and other types of surface preparation.

        The tooling and production practices used to manufacture our fiberglass components employ the latest techniques and materials available to the aerospace industry.

          This allows RHCI to build parts that are one-third the weight of those using conventional wet lay-up techniques, practiced by most aircraft manufacturers. Composite technicians at RHC are meticulously trained to build, maintain, and repair all molds, their expertise guarantees the quality and uniformity of all parts.


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Main Rotor Blades Department

          The heart of any rotorcraft is its rotors. These airfoils move with incredible speed at the tip, creating dynamics which require precision balancing.

          RHCI's rotor blades are fabricated using an aluminum extruded leading edge, mated with an incredibly rigid machined foam core, then covered with carbon pre-peg fiberglass.

          The result is a stiff, strong, lightweight and durable rotorblade with a lifetime conditional warranty.

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Coatings Department

          RHCI utilizes its environmentally friendly paint booth to coat its metal components to protect them during storage, shipping and assembly. This ensures proper corrosion protection and part longevity.

          The company continually evaluates the latest high-tech coating processes for use in its products: analyzing application implications, environmental safety factors, weight contribution impact and the overall effect on long-term component durability.

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          RHCI's blade balancing techniques are on the leading edge of technology. A Master Craftsman balances each blade to within.00/lb., using custom made digital balancing equipment.

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          Critical components, such as the main rotor blades, are sanded and finished in-house to achieve the proper airfoil shapes enabling RHCI's aircraft to meet its high standards of efficiency.

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Shipping & Receiving

          RHCI is unique in the user-built aircraft industry, in that it ships only complete kits. This last step in the manufacturing process is very important in the presentation of the kit. This begins with a computerized parts inventory, which tracks each component from the time it is received to the time it is shipped; giving critical information on parts availability and location at any point in the production process.
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          Parts and sub-assemblies are packaged, coded and placed on clearly marked vacuum packed cards, then sealed into place, to protect against loss during shipping. The customer simply cuts the parts from the card when needed, keeping the remaining components organized on the card.

          RHCI maintains a large inventory of parts and has most components on hand at all times. This ensures favor able pricing from vendors and manufacturers through volume purchasing.

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          Prior to shipping, the packing list is compared to a hands-on parts inventory, and these are double checked for accuracy. Parts are digitally counted by a computer based on the weight.

           Aircraft parts are individually wrapped and enclosed in wooden crates for safe shipment anywhere in the world. Each crate is then logged into our computerized tracking system, which enables RHC to know a crate's location at any time.

          RHCI provides a comprehensive spare parts support system. Orders can be placed by telephone, fax or e-mail, replacement parts are shipped within three business days if they are in-stock.


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RHCI Around the World

          RHCI attends major airshows and rotorcraft events both nationally and internationally RHCI's foreign distributors attend most major air shows in their respective countries. RHCI frequently supports special interest airshows for the military, law and drug enforcement officials, yachting enthusiasts and other special interest groups

          RHCI continues to pass important milestones as it continues to expand its horizons, RHCI is known worldwide as the fastest growing helicopter company in the world! Providing global markets with helicopters that are affordable to purchase, operate and maintain, is only the first step in a larger strategic plan. The company plans to continue developing products and services that meet both the present and future needs of our Customers.

          RHCI's enthusiasm and strong commitment to aviation, its aggressive design philosophy, and increasing technical knowledge, will allow it to expand the current product line well into the next century.

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