Improved LEAP 1A Engine Covers: The Creative Process Behind Prototyping the New Design

Magnetic Creative

Innovation often stems from identifying the problem. For the Magnetic Creative team, spotting the potential issues with the current engine covers design for the LEAP 1A engine provided the opportunity to showcase skills and creative thinking to come up with a simple yet viable solution.

“It all began with a keen observation from a potential customer who expressed the need for specialized engine covers for the Leap 1A engines. We conducted extensive market research and saw the widespread usage of Leap 1A engines in the Airbus A320neo series. Recognizing the potential in this niche, we were determined to create a solution that would redefine aircraft engine protection,” shared Oleg Soovik, Interior Workshop Supervisor at Magnetic Creative.

To launch the design process, the Magnetic Creative team collaborated closely with the Magnetic MRO Base Maintenance team, who shared valuable insights. The Creative team took precise measurements, that laid the foundation for a prototype and pre-fit process. According to Oleg, this collaboration was not “just helpful”, but also validated the necessity for improved cover design. Collaboration between Magnetic Group business units allowed the team to ensure that the product they were creating could be seamlessly integrated with LEAP 1A engines.

With measurements in hand, the team entered the prototyping phase. Piret Saartok, Sewing Technologist at Magnetic Creative, shared: “The prototyping stage is instrumental in perfecting the design and creating a top-notch product. Various fabrics were tested, to pick the most lightweight and durable solution. Through this process, we saw areas for additional improvements. For example, we incorporated pockets for pins, which allow to keep the aircraft from potential damage. Normally, pins are left dangling – and when exposed to elements, such as wind, they could damage the engine. So, pockets were a simple yet smart addition.”

According to Piret, the design has been crafted not only thinking about innovation but also the end-users of the product – mechanics, “We aimed to create a product that would provide the needed protection, as well as be comfortable to install and remove.” Additionally, the chosen lightweight material and final design allow the crafted engine covers to fold into a bag neatly. These are a few elements that ensure smooth usage without compromising in quality.

“After an intensive development journey, we proudly present our Engine Inlet and Exhaust covers for Leap 1A engines – a product born out of passion, collaboration, and precision engineering. Each cover shows our commitment to excellence and our dedication to meeting the unique needs of aviation professionals,” concluded Oleg.