Why Henchman Shadow Foam Outperforms Standard Tool Control Foam

Many customers are surprised to learn how much engineering goes into every tray we produce. Here’s a closer look at what makes Henchman shadow foam different from standard tool control foam systems.

When it comes to professional tool control, not all shadow foam is created equal. At Henchman, our foam system has been engineered specifically for demanding environments such as aviation maintenance, where durability, precision, and long-term usability are critical.

Engineered Three-Layer Construction for Strength and Precision

Henchman foam trays are built using a three-piece thermally bonded structure, designed for durability and clean shadowing.

The top layer features a hard plastic sheet that can be laser engraved with tool sizes, part numbers, or custom identifiers. This allows permanent labeling while also protecting the foam from scratches, dents, and daily wear.

The rigid top surface also adds structural strength to the tray, helping it maintain its shape even in high-use environments.

Black Shadow Layer for Clear Tool Visibility

Directly beneath the top sheet sits a 5 mm black shadow layer.

This layer creates the sharp visual contrast that gives shadow foam its name. The defined black shadow makes it easy for technicians to instantly identify missing tools at a glance.

In busy maintenance environments, this simple visual cue significantly improves tool accountability and inspection speed.

Henchman Blue Base Layer for Maximum Contrast

The bottom layer features our signature bright Henchman Blue foam.

When a tool is removed, the contrast between the black shadow layer and the blue base layer makes the empty space highly visible. Missing tools stand out immediately, supporting strict tool control procedures in aviation and engineering environments.

Additional Rigidity for Lift-Out Trays

For trays designed to be removed from tool cabinets, we add another structural feature.

A reinforcing plastic sheet is bonded to the bottom of the tray, providing additional rigidity. This allows technicians to confidently lift a fully loaded tray with one hand without flexing or bending.

It’s a small detail, but one that significantly improves everyday usability.

Unique High-Density Closed-Cell Foam

All Henchman foam trays are manufactured from high-density closed-cell foam, specifically chosen for demanding tool control environments.

Unlike many generic foams used in standard tool organisers, this almost solid material is selected to deliver the durability and machining quality required for precision CNC-machined shadow foam trays.

The foam provides:

• Long-term durability in high-use environments
• Clean CNC machining for precise tool cut-outs
• A consistent, professional finish across every tray

Because the foam is closed-cell, it will not absorb oils, chemicals, or moisture. It is also resistant to Skydrol, making it suitable for aviation maintenance environments.

The material also resists compression and deformation, ensuring tool trays maintain their shape, structure, and visibility for years of daily use.

Designed for Professional Tool Control

Every Henchman foam tray is engineered with the same goal: clear tool accountability, long service life, and efficient workflow for technicians.

If you would like more insight into our shadow foam systems or need help designing a layout for your tool set, feel free to reach out. We’re always happy to help customers create clean, efficient, and reliable tool control solutions.

Meet us at these major US Tradeshows

Henchman will be exhibiting their toolkits and tool control solutions at the follwing tradeshows in 2026: 

1. Verticon 9-12 March in Atlanta, Georgia, Booth B8423
2. PartsBase Expo 11-12 March in Miami Beach, Florida, Booth 1075
3. AAAA Defence Summit 15-17 April in Nashville, Tennessee, Booth 424
4. MRO Americas 21-23 April in Orlando, Florida, Booth 4650

Find out about

• our new range of pre-designed aircraft maintenance Tool Kits
• how easy to create and flexible our custom-build Tool Kits really are
• how our Electronic Tool Control Solutions automate your tool control and make it effortless
• all the aircraft tool brands we supply, listed in our 700 page Aerospace catalogue

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Instant Toolkit Status Visibility Across the Hangar

Save time and avoid long walks and drawer checks with this version of the kabTRAK. In large aircraft maintenance facilities, checking whether a toolkit is complete can slow down operations, interrupt workflow, and take valuable minutes away from critical tasks. What if you could know the status of every toolkit instantly, without leaving your workstation?

With the patented kabTRAK Electronic Tool Control System, maintenance teams gain real-time visibility of toolkit completeness, helping them work smarter, faster, and more efficiently — keeping aircraft maintenance operations on schedule.

What is kabTRAK?

kabTRAK is a unique electronic tool control system designed to track and manage aircraft maintenance tools and toolkits in real time. It ensures that every tool is accounted for, reduces the risk of misplaced items, and supports compliance with aviation safety regulations.

By integrating with optional visual indicators, such as a red/green signal pole, kabTRAK allows maintenance personnel and supervisors to see toolkit status at a glance, without walking across the hangar or opening every cabinet.

Find out more about this unique inventory control solution on www.henchmanTRAK.com

How Instant Toolkit Visibility Works

The red/green signal pole is directly connected to the top of the kabTRAK drawer cabinet:

• Green light: All tools are in place; toolkit complete

• Red light: One or more tools are removed or missing

This simple yet powerful visual cue provides 360-degree visibility of toolkit completeness, reducing unnecessary movement and ensuring teams can confirm kit status in seconds.

Benefits of Real-Time Toolkit Visibility

Implementing kabTRAK with visual status indicators offers clear operational benefits:

• Instant visibility: Know toolkit completeness from anywhere in the hangar.

• Time savings: Minimize walking and streamline workflow.

• Enhanced oversight: Supervisors can quickly verify tool accountability.

• AOG-ready: Immediate awareness of missing tools helps prevent delays.

• Compliance and safety: Maintain strict tool control and audit readiness.

These benefits are particularly valuable for large aircraft maintenance operations, where toolkits are shared across multiple workstations, such as in Airbus A380 hangars.

kabTRAK in Action

Two kabTRAK cabinets equipped with red/green signal poles are soon being deployed in Melbourne, supporting A380 maintenance in a dedicated hangar. With this system, technicians and supervisors can instantly see toolkit completeness, improve workflow efficiency, and reduce downtime.

Watch our video reels on Instagram @henchmantools to see kabTRAK and the signal pole in action.

Why Aircraft Maintenance Teams Choose kabTRAK

Airlines and MRO (Maintenance, Repair, and Overhaul) facilities worldwide rely on kabTRAK because it:

• Tracks tools in real time

• Supports efficient tool accountability

• Reduces time wasted checking kits manually

• Digitally logs all tool movements, including user, time, tail number, tool condition and calibration deadlines

• Enhances hangar-wide visibility of kit completeness

• Helps prevent AOG (Aircraft on Ground) delays

By providing instant visibility of toolkit status, kabTRAK improves hangar efficiency, reduces operational risks, and keeps aircraft maintenance teams focused on what matters most: keeping aircraft flying safely.

What is the best Foam for Tool Kit Drawer Organization?

Not being able to find a particular tool when you need it is more than just an inconvenience. The time spent looking for it reduces your productivity, in addition to feeling stressed and annoyed.

Organizing your tools in Foam Drawer Inlays makes sure a tool is always returned to its allocated location, making it easy to find. This type of visual tool control also makes it easy to identify which of your tools are actually in your tool storage (toolbox, toolkit, drawer cabinet or even wallboard) or out – which means you need to find and return them.

• Significantly reduce time wasted on searching for a tool – every tool has its dedicated spot in the toolbox
• Reduce time figuring out which tools are missing – immediately see which tools are in use
• Reduce cost of replacing tools accidentally left behind
• Reduce cost for scratched or damaged tools – every tool is protected by the foam and stays in its place
• Work professionally with a clean and organized toolkit
• In Aviation: Follow the requirements of CASR/EASA Part 145 compliance regulations

But which foam type is most suitable when it comes to creating your own tool foam inserts? Read more about the types of foam that can be used for tool organization below, ranked by density.

Closed-cell Foam vs Open-cell Foam

Foam cells are bubbles that expanded from the liquid foam mixture during its production. In open-cell foam, these bubbles expand until they burst, leaving behind an interconnected structure, called struts. In closed-cell foam sheets, cells do not rupture, and the thin surfaces between the struts are called windows.

Open Cell Foam Types: Polyurethane (PU), Latex Foam, Dryfast Foam are recognizably soft and have a squishy spongy feel. Even though they are good for packaging, they are not sturdy and durable enough for drawer foam inlays, as they can easily break or rip (increasing the risk of foreign object damage (FOD) in Aviation).

Closed Cell Foam Types: Cross-linked polyethylene (XLPE), polyethylene roll and standard polyethylene (PE) are more rugged and durable, in addition to NOT being water absorbent.

What are Henchman Foam Inlays made of?

The foam for our tool kits has been specially formulated to be the top of its class and specifically designed for custom case inserts and tool foam inlays. It is only available from us.

The distinctive black and bright blue Henchman foam sheets are made up of 4 layers:

1. A solid plastic top layer, wipeable and can be laser marked.
2. A thin black foam layer for heightened contrast and protecting your fingers from potentially sharp edges.
3. The main bright blue foam layer, which is a custom blend of XLPE and EVA Foam.
4. A thin plastic bottom layer, providing rigidity and protection against scratches and moisture.

Minicel Foam / EVA Foam (chemically crosslinked ethylene-vinyl acetate)

Minicel foam is a fine-celled foam of superior quality making it ideal for projects that require a thicker foam for durability and longevity. Minicel foam is a high-performance ethylene-vinyl acetate (EVA) foam that is more resilient than crosslinked polyethylene foam (XLPE). With a smooth and consistent surface, coupled with exceptional physical and chemical properties, Minicel offers a reliable solution for a wide array of applications in which durability is paramount.

Minicel closed-cell foam works well as thermal insulation, industrial gaskets, padding in sports and work equipment, shin guards, helmets, insulating hot tubs, yoga mats or exercise mats. In addition, it can be used in boating and marine as boat deck mats, flotation equipment, custom seating and padding in kayaks – due to its low moisture permeability and high buoyancy.

• Superior resiliency
• Fine-celled
• Matte finish
• Toughness with great flexibility
• Low water absorption
• Impervious to mildew, mold, rot, and bacteria
• Good thermal insulator
• Excellent chemical resistance
• 100% recyclable

While the foam inlay shape itself is easily cut with a sharp utility knife, scalpel, or hot blade, EVA and XLPE foam types require a CNC router or Dremel to cut the individual tool pockets. This makes them less suitable for DIY tool drawer organization.

Cross-Linked Polyethylene Foam (XLPE Foam)

Chemically cross-linked polyethylene foam is an extremely fine closed-cell foam, ideal for applications that require thicker foam. With a more smooth and pleasant feel than EVA foam, combined with superior physical and chemical properties, cross-linked polyethylene foam can be used in a similar array of applications.

XLPE or Polyolefin Foam works well commercially as thermal insulation, construction expansion joints, and industrial gaskets. It is also used as packaging and in flotation equipment. XLPE can also be carved and sanded for one-of-a-kind DIY projects.

• Resilient
• Extremely fine-celled
• Matte finish
• Excellent strength and shock absorption
• Low water absorption
• Excellent buoyancy
• Impervious to mildew, mold, rot, and bacteria
• Good thermal insulator
• Excellent chemical resistance
• Nontoxic and contains no CFCs, HCFCs, or hydrocarbon blowing agents
• 100% recyclable
• Similar to Volara in the US, Alveolit in Europe and Softlon in Japan and Australia

Volara foam is a general-purpose Polyolefin foam, but FDA approved for use in food and other health applications, due to its strong chemical and microbe resistance.

The two foams with the finest cellular structures are neoprene and cross-linked polyethylene (XLPE). They are constructed of incredibly small cells, even though they might look and feel more like a solid piece of flexible plastic or rubber.

Neoprene Foam

Neoprene foam, dark charcoal grey in color and also known as “Monarch”, is a soft, flexible, and durable form-fitting sponge rubber that provides good thermal and moisture insulation. It is resistant to ozone, sunlight, oxidation, as well as many chemicals and petroleum derivatives. Neoprene will also resist breakdown by water and air because of its unique molecular rubbery structure. Practical applications of neoprene foam include sports equipment like wet suits, gloves, knee pads, and elbow pads. In an industrial capacity, neoprene can be used as insulation, expansion joint filler in masonry and concrete work, gaskets, and weather stripping.

Both neoprene and XLPE are consistent throughout the sheet, without getting denser near the outer edges. Neoprene is a dense, more rubbery material, in most formulations softer and more flexible than XLPE, while cross-linked polyethylene is more rigid while usually being lighter.

Although most commonly known as a thin sheet, Neoprene is also available in thicker blocks that can be cut with a sharp utility knife, scalpel, or hot blade.

Standard polyethylene foam (PE Foam)

Polyethylene foam is a strong and resilient shock absorbing closed cell foam, ideally suited as packaging and padding. Polyethylene is available in sheets, cylinders, and tubes that are used for expansion joint filler (backer rod), insulation, buoyancy components, and packaging. Being more plastic-like than other foams, PE has a sheen, unlike the matte finish of the closed-cell foams above, that appear more rubbery.

It is versatile and can be used across a wide range of applications, from archery targets and long term storage to sill plate gaskets and bond breaker in masonry work. It is also made in an Anti Static formulation for the storage, packaging, and transportation of sensitive electronics.

• Closed cell, chemically cross-linked structure
• Glossy finish
• Lightweight
• Shatterproof
• Non-dusting
• Excellent buoyancy
• Superb strength and tear resistance
• Excellent shock absorption
• Impervious to mildew, mold, rot, and bacteria
• Superior water, chemical and grease resistance

The cells of polyethylene are rather large, similar to Dryfast, but are completely sealed off as enclosed cells. Lower density PE consists of larger cells and high-density PE consists of smaller cells.

PE is used for most Cut and Peel foam inlays. For tool drawer organization applications, the top layer of the foam can be cut using a utility knife before peeling it off the bottom layer, making it suitable for most DIY tool foam projects. But in the Aviation industry it can turn into a safety hazard called foreign object debris (FOD) due to the layered structure of the foam – when parts of the foam layer peel off.

It also is a lot softer than XLPE or EVA and therefore more suitable for tool organization in toolbox drawers - not for multiple inlays stacked inside a portable case, that are meant to be taken out of their case.

Pick and Pull Grid Foam

Pick and Pull Grid Foam is a lightweight low-density variant of polyethylene (PE) foam with a cube design precut into the top layer, making it easy to grab and pull a square to create a basic cutout to fit around any size or shape object. Absorbing impacts and vibrations, it is strong enough to protect the contents of a package without drastically increasing the weight, keeping shipping costs to a minimum. Applications include mailing artwork or breakables, storing firearms, weapons, and bulkier equipment, as well as computer parts. Other applications include cost-effective acoustics, cases, and packaging.

The foam-filled options of the Explorer Transit Cases Range come with this kind of foam.

Expanded Polystyrene Foam (EPS) / Styrofoam

Expanded Polystyrene (EPS) has the most unique foam cell structure among closed-cell foam, and as a result, is the most recognized. The omnipresent white foam, typically seen as coffee cups and packaging material, is also known as “bead board” because of its cellular structure. During the material’s formation, tiny beads of styrene expand to more than 40 times their original size and are compressed together into blocks, sheets, and molded shapes. These beads are easily visible and can be picked out.

Nevertheless, Polystyrene foam is a sturdy and lightweight foam that’s very popular for personal projects like arts and crafts, as well as for commercial uses like geotechnical filler in construction. Surprisingly strong, EPS’s unique closed cell structure offers excellent resistance against moisture and water vapor, and will not rot, mold, or mildew. EPS sheets have a superior R-value which makes them an outstanding insulation product in homes and as hot tub covers.

EPS requires hotwire cutting for smooth edges, otherwise it tears and flakes into its beads. This characteristic also makes it unusable in Aviation Tool Kits, as it poses a very high risk of breaking and becoming Foreign Object Debris (FOD).

Expanded Polypropylene Foam (EPP)

Being a rigid closed-cell foam material with great compression and impact resistance, Expanded Polypropylene is a versatile material that can be used for many applications. With a broad loading range, high energy absorption, and great servicing temperature, EPP is ideal for displays, packaging, thermal insulation, heavy duty packaging, signage, roofing strips, and more.

EPP is used widely in the aero modelling hobby due to its superior strength and its resistance to aero fuels. High density grades are used where energy management is important, such as automotive bumpers and interior passenger safety components. Low density grades are used for packaging applications, and medium densities find applications in furniture and other consumer products.

Similar to EPS, EPP also requires hotwire cutting for smooth edges, otherwise it tears and flakes into beads.

Would you like to organize your tools in Henchman foam inlays? Contact us to chat about your requirements.

Holiday Season Office Closure Announcement 

As we approach the festive season, we want to take a moment to wish all our customers, partners, and hard-working team members a very Merry Christmas and Happy New Year!

In keeping with the spirit of the holidays, our office will be temporarily grounded for a much-needed downtime. Please note, our office will be closed between 12/24/2025 and 1/4/2026 to allow our team to enjoy the holiday season with family and friends.

Order Fulfilment During the Holidays:
Our team will be doing a thorough pre-holiday check to ensure all urgent orders have been shipped before we wrap things up for this year. We'll be back and ready to help you keep your fleet flying smoothly in 2026. 

For any urgent tooling needs or quotes during this time, please feel free to contact us via au.sales@henchmantools.com, and we'll get back to you as soon as we can.

Stay safe, stay jolly, and keep your engines running smoothly! 

Why Torque Wrench Accuracy Matters in Aircraft Maintenance

In aircraft maintenance and MRO operations, torque accuracy is critical for structural integrity, system reliability, and regulatory compliance.
A torque wrench that delivers incorrect readings can compromise safety, damage components, and cause costly rework.

While scheduled torque wrench calibration provides a baseline for accuracy, tools can lose precision between calibrations. This risk is especially high in busy facilities where:

• Multiple torque wrenches are in use daily by different engineers.
• Handling and storage practices vary between operators.
• Calibration compliance is judged solely by the date on the label.

Common Causes of Torque Wrench Inaccuracy

Even if the calibration date is still valid, torque wrenches can be affected by:

• Spring relaxation – Prolonged storage at high torque settings reduces internal spring tension.
• Mechanical shock – Drops or impacts may shift internal calibration.
• Graduation misalignment – Difficult-to-read torque scales increase the risk of incorrect settings.

Relying only on calibration labels risks undetected inaccuracies that can lead to incorrect torque on critical fasteners.

The Solution: Aviation Torque Confidence Testing

A Torque Confidence Tester is designed to verify the accuracy of torque wrenches between calibrations — without sending tools off-site.
This point-of-use torque verification process provides immediate assurance that your tools are delivering precise torque values before they are used on the aircraft.

Key features of our Aviation Torque Confidence Tester include:

• Four precision transducers covering 3 Nm to 2700 Nm / 2.5 in·oz to 2000 ft·lb.
• User-friendly software – enter the target torque, perform three readings, and receive an instant Pass/Fail result based on your tolerance.
• Full range of drive adapters, organised in CNC-machined tool control foam for quick access.

Benefits of Integrating Torque Confidence Testing

Implementing torque wrench verification as part of your daily maintenance workflow delivers:

• Immediate accuracy assurance before performing critical tasks.
• Reduced downtime – avoid unnecessary tool withdrawal for recalibration.
• Improved compliance with EASA, FAA, and OEM maintenance standards.
• Cost savings – identify damaged tools early and prevent rework or component failure.

Conclusion

A Torque Confidence Tester closes the gap between scheduled calibrations, ensuring your torque wrenches are accurate and safe to use at all times.
By making torque tool verification a standard part of your maintenance process, your facility strengthens quality assurance, enhances operational safety, and reduces the hidden costs of torque inaccuracy.

Download Info Fact Sheet or arrange a demonstration today.

Effortless Use, Seamless Compliance: With the New Aircraft Tool Kit Range!

In the fast-paced world of aviation maintenance, ensuring tool control and compliance is critical to maintaining both safety and efficiency. That’s why we’re excited to introduce our new range of Aircraft Maintenance Tool Kits - designed with ease of use in mind, while helping you stay compliant every step of the way.

Why Tool Control Matters

Visual Tool Control isn’t just about keeping your tools organized - it’s about maintaining safety standards and minimizing the risk of tool loss or damage during aircraft maintenance. Losing a tool in the engine bay, for instance, can cause significant delays and even lead to costly damage. Proper tool control procedures prevent such mishaps and help ensure that every part of your aircraft is handled with precision.

A Smarter Way to Stay Compliant

Our new MRO tool kits brochure focuses on making tool control simpler than ever. We’ve streamlined our range of aviation toolkits to ensure they meet the latest industry standards for compliance, all while making them easy to use in your day-to-day operations. Whether you’re an B1 or B2 LAME mechanic, A&P or AMT technician for avionics maintenance, mechanical maintenance, or structural maintenance, you’ll find that our kits and systems save you time and headaches by keeping your tools organized, accounted for, and easy to access.

Features of the New Aircraft Tool Control Brochure

• Compliant: Compliant foam inlays, ensuring our tool control solutions meet industry requirements and regulations.
• Easy to Use: Intuitive designs and user-friendly systems that ensure maximum productivity.
• Durable: Tools, foam and storage solutions built to last, even under the harshest conditions.
• Customizable: Tailor your tool kit to the specific needs of your aircraft maintenance environment.

How It Works

Our new range of kits was specifically designed with efficient tool control in mind. From portable and wheeled toolboxes with dual colour shadow foam inlays to electronic automated tool tracking, each product is engineered to ensure you’re always in compliance with the highest safety standards. Plus, our solutions integrate seamlessly into your daily workflow - reducing the time spent on tool management and allowing you to focus on what truly matters: keeping aircraft in top condition.

Select a pre-designed kit from our new cornerstone range of aircraft maintenance toolkits or customise it to your specific requirements - the choice is yours.

Next Steps: Get Your Brochure Today

Ready to take control of your tool management? Download our Henchman Aircraft Maintenance Tool Kit Brochure (PDF, 6.4MB) today and see how easy compliance can be. Stay organized, stay efficient, and stay safe - all while keeping your maintenance operations running smoothly.

In case you prefer a print copy, visit us at one of the upcoming tradeshows or contact us.

Meet us at MRO Americas 2025 in Atlanta

Henchman will participate in this years MRO Americas at the Georgia World Congress Center, Atlanta, GA. 

On booth 4517 (see the latest floorplan here) you will be able to find out about

• our brand new range of standard maintenance Tool Kits
• how easy to create and flexible our custom-build Tool Kits really are
• how our Electronic Tool Control Solutions automate your tool control and make it effortless
• all the aircraft tool brands we supply, listed in our 700 page Aerospace catalogue

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Meet us at Verticon Vertical Aviation Tradeshow 2025

Henchman will exhibit at this years Verticon at Kay Bailey Hutchison Convention Center, Dallas, Texas. 

On booth 4222 (see the latest floorplan here) you will be able to find out 

• about our new range of standard tool kits!
• how easy to create and flexible our custom-build Tool Kits really are
• how our Electronic Tool Control Solutions automate your tool control and make it effortless
• all the aircraft tool brands we supply, listed in our 700 page Aerospace Print Catalogue

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Meet us at MRO Americas 2024 in Chicago

Henchman will participate in this years MRO Americas at the McCormick Place Convention Center, Chicago, IL. 

On booth 4845 (see the latest floorplan here) you will be able to find out 

• how easy to create and flexible our custom-build Tool Kits really are
• how our Electronic Tool Control Solutions automate your tool control and make it effortless
• all the aircraft tool brands we supply, listed in our 700 page Aerospace Print Catalogue

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Meet us at HAI Heli-Expo 2024 in Anaheim

Henchman will participate in this years HAI Heli-Expo at the Anaheim Convention Centre in Anaheim, California. 

On booth 8233 (see the latest floorplan here) you will be able to find out 

• how easy to create and flexible our custom-build Tool Kits really are
• how our Electronic Tool Control Solutions automate your tool control and make it effortless
• all the aircraft tool brands we supply, listed in our 700 page Aerospace Print Catalogue

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Why Fall Protection is Crucial in Aviation Maintenance

In 2022, 30 aircraft mechanics in the United States (US) were severely injured while working, according to new data released by the US Occupational Safety and Health Administration (OSHA). This is double the yearly average of 15 severely injured aircraft mechanics recorded between 2015 and 2021 (with 19 recorded in 2017).

12 of these 30 severe injuries were falls, resulting in fractures, amputations, internal injuries, and puncture wounds. Seeing as falls made up the largest portion of the severe injuries recorded in 2022, it is clear more needs to be done to prevent them in the first place.

Which Fall Protection Solution Can I Use for My Employees' Safety

The manufacturer MSA Safety is combatting falls in the aviation industry by providing the vacuum-based fall protection solution known as the MSA Latchways WinGrip System.

This ground support equipment (GSE) is designed for fixed wing aircraft maintenance, fuselage inspection, as well as light aircraft manufacturing and maintenance, and can be fixed to the wings, fuselage, or stabilisers of an aircraft. Workers wearing full-body harnesses attach to the system through work positioning ropes, enabling hands-free maintenance access.

MSA says the lightweight (6kg) system is tested and rated for fall arrest, and engineered to safely support twice the expected load, limiting load transferred to the aircraft structure.

It is approved for use on the entire Boeing aircraft fleet and listed in the Airbus Aircraft Maintenance Manual (AMM) as the only system to be used for fall protection on any Airbus aircraft.

Flexible, Versatile, and Intrinsically Safe Fall Protection

The WinGrip® range now consists of four systems and has been designed in a modular way, incorporating interchangeable components. This gives users more choice and flexibility when resolving worker fall protection issues.

All four WinGrip fall protection solutions are easy to install and run on compressed air or nitrogen, removing the requirement for electricity. They are therefore not only usable in both wet and dry conditions, inside and outside the hangar, but also usable around open fuel tanks. Additionally, WinGrip has been independently tested to meet all relevant international standards, while no metal-on-metal contact protects the aircraft surface and minimizes the sparking risk.

The Four WinGrip® Aviation Fall Protection Solutions

MSA Latchways WinGrip® All-in-One (AIO) System – Remote Flightline Line Maintenance Checks

MSA also offers the Latchways WinGrip All-in-One (AIO) System vacuum anchor, which is designed for flightline or quick hangar tasks.

The company says the certified fall arrest system and fall restraint system are intended for personnel working on aircraft during manufacturing or maintenance operations.

Due to its lightweight, compact, and intrinsically safe design, the WinGrip AIO System can be used inside or outside. As the System is powered by either compressed air or nitrogen, MSA says the working temperature range varies from arctic freezing to extreme desert.

Additionally, the company says the WinGrip AIO System is quick to deploy and easy to use on walking wing areas or structural fuselage sections and features a removable and rechargeable gas bottle.

Once the vacuum pad has been locked into place, users can attach to the system by wearing a full-body harness and work positioning ropes to enable hands-free access for all required maintenance.

MSA Latchways WinGrip® Single-User System – Short-Term Fall Protection for One Worker

Since 1999, the WinGrip System vacuum anchor has provided a single fall protection anchor point for a single worker on the wings, fuselage, or stabilisers of an aircraft. Designed for line maintenance and other short-term work, the anchor is positioned, and vacuum locked into place.

While in use, the worker wears a full-body harness with a safety lanyard and work positioning rope connected to the vacuum anchor, providing a 10ft (3m) safe working radius for comfortable hands-free movement. Additionally, two vacuum anchors can be used to triangulate and fix worker positioning.

MSA says the WinGrip System can be installed and used in minutes, additional workers can be supported with extra WinGrip vacuum pads, and it is easily upgraded to the Lifeline System.

MSA Latchways WinGrip® Lifeline System – Heavy Maintenance and Long Access

The WinGrip Horizontal Lifeline System can accommodate up to four workers along the entire length of a wing or fuselage for construction, heavy maintenance, or return operations.

This wingwalking lifeline system consists of two-ended anchor vacuum pads with cables spanning in between, and intermediate anchors used as needed to suit any cable length. Each anchor is positioned and vacuumed locked in place, followed by stainless steel safety cables connected and tensioned at one end.

MSA says workers connect cables using the unique Latchways shuttle while employing full-body harnesses and work position ropes. This enables hands-free movement along the entire cable length, while the shuttles glide over intermediate anchors.

MSA Latchways WinGrip® Barrier System – For Any Duration Without Harnesses

The WinGrip® Barrier System is designed as a working-at-height solution during aircraft manufacturing and maintenance. The system can be installed by a single user and provides an enclosed environment for unlimited workers indefinitely.

WinGrip® Barrier System reduces fall risk by providing superior safety at heights, with workers only requiring basic training to work within the system without needing harnesses and lanyards.

The system consists of upright stanchions connected at the base to a WinGrip® System vacuum pad, while the stanchion interface is fully adjustable, ensuring correct installation can be achieved on any undulating surface.

Horizontal rails are adjustable in length and angle, allowing any system shape to be installed and adjusted at any time. MSA says the system is scalable from 1m-square to the entire upper surface of an aircraft.

More than 100 Years of Safety Solutions

MSA, who was named as one of the most responsible companies in the US by Newsweek says multiple-user cable-based systems or single-user anchor options can be tailored to each customer’s needs.

Commenting on the nomination by Newsweek, MSA Safety Senior Vice President, Chief Legal Officer, Corporate Social Responsibility and Public Affairs, Stephanie Sciullo says helping to protect people at work has been a single focus of the company for more than a century.

“It’s what inspires our people to design, deliver, and manufacture the world’s leading safety solutions that help to protect the people who put their trust in the MSA brand. This is purpose at work.”

Henchman is a Supplier of Fall Protection Systems in the USA and Australia

Henchman Tools is an international single-source supplier of premium hand and power tools, specialised tooling solutions, and custom-designed toolkits renowned for their superb quality finish and design.

As one of three distributors of MSA’s WinGrip System in Australia, we can import and supply this crucial safety device to any aviation and aerospace companies both locally and internationally.

Do you think MSA Safety’s WinGrip® System could help you work more safely and efficiently?

Send us an email to sales@henchman.com.au or give us a call at +61 2 4956 7111 to find out which WinGrip® System best fits your needs.

Meet Us At MRO Americas 2023 in Atlanta

Henchman will participate in this years MRO Americas at the World Congress Centre in Atlanta, Georgia. 

On booth 5127 (see the latest floorplan here) we will be showcasing

• our new Aerospace Print Catalogue with 700 pages of Aircraft Tools
• our Electronic Tool Control Solutions kabTRAK, portaTRAK and cribTRAK
• Toolkitting Solutions and Visual Tool Control using Shadow Foam
• Storage Solutions by Explorer Transit Cases
• Rugged Electronic Devices by Durabook

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Meet Us At HAI Heli-Expo 2023 in Atlanta

Henchman will participate in this years HAI Heli-Expo at the World Congress Centre in Atlanta, Georgia. 

On booth B3314 (see the latest floorplan here) we will be showcasing

• our new Aerospace Print Catalogue with 700 pages of Aircraft Tools
• our Electronic Tool Control Solutions kabTRAK, portaTRAK and cribTRAK
• Toolkitting Solutions and Visual Tool Control using Shadow Foam
• Storage Solutions by Explorer Transit Cases
• Rugged Electronic Devices by Durabook

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

New Aerospace Tools Print Catalogue 2023

You can now find our comprehensive Aerospace Tools range in one practical print catalogue. Flick through the 700 pages, make notes and browse all categories, including:

• Electronic Tool Control, Storage Solutions, Customisable Toolkits
• Drilling, Reaming & Cutting
• Grinding & Sanding
• Riveters & Riveting
• Sealant Application & Removal
• 1/4, 3/8, 3/4 and 1 inch Sockets & Ratchets
• Spanners & Wrenches
• Striking, Hooks & Pry Bars
• Drivers & Screw Extraction
• Pliers, Cutters & Shears
• Cable Strippers & Crimpers
• Clamps, Vices & Pullers
• Fluke Test Equipment
• Avionics Laboratory/PCB Level
• Force, Tension & Torque
• Inspect, Measure & Lighting
• Miscellaneous

Request a free Print Copy or Download it here (PDF 58MB). 

The Challenges Of Part 145 - Keeping Efficiency Is Paramount

Tooling Coordinators and Base Maintenance Managers are faced with meeting compliance issues and can find it extremely daunting which way to turn - on the one hand with pressure from aviation authorities and on the other from their mechanics objecting to change.

Compliance requirements remain through these troubled COVID-19 times and whilst the volume of flights no doubt have dropped off radically, these requirements remain. Funds may not be so great at this time but it could be the best opportunity to get on top of things in preparation for getting back into the whirlwind.

As we are aware, CASR Part 145 requires suitable accountability of tools/equipment, suitable procedures to avoid FOD and correct calibration management of tools/test equipment within specified date requirements. Meeting these requirements can be seen as creating a whole lot of extra work, red tape and delays when time is so precious. Is this how your company feels?

Some points from our experience as a solution providing company:

Visual Tool Control For Tool Kits And Drawer Cabinets

After working with many airlines around the world we have prove that with the introduction of good tool control procedures, the efficiency levels and user experience is considerably enhanced.

Whilst the mechanics often buck against switching from privately owned toolkits to company owned, it is unquestionably proven that working from standardised company-owned toolkits does reduce FOD potential and saves a considerable amount of time.

Company-owned toolkits with quality tools set out in a sensible way in two-coloured shadow foam places tool control right up on the work-front. No longer does it take an hour or more to do an inventory-check on your toolbox. Actually it takes as long as a glance on each layer.

Previously these inventory checks may have been required to be performed say once a week by every mechanic on their personal-owned toolkit. Consider the cost in time!

The Downside of Manual Tool Management

Manual systems can be put in place to manage toolkits, hand tools and equipment. If done suitably, full accountability at any time can be proven, it certainly meets compliance requirements and can go a long way to meeting the need.

However, toolkits, tools and equipment have to be stored securely, issued as complete and returned as complete requiring much human resource to accurately do so with manual methods. This could include signing in and and out, a storeman checking every kit or piece of equipment in and out of the toolcrib.

The question is, do you believe your system will provide 100% accountability for all your tooling at a moments notice?

Electronic Tool Control in Tool Cabinets

Automated Electronic Tool Control Systems to suit hand tools in drawers is not as simple as it sounds. There are less than a handful of companies who produce anything along these lines and even from this handful most are unable to manage small items like 1/4" Drive Sockets, Screwdriver Bits, Cutting Tools, etc.

When the discussion of electronic tool control comes up many think RFID is the state-of-the-art solution, where in fact it is almost impossible to successfully tag all the required small tools. Successfully reading all tags when a kit may comprise of 1,000 plus tools in a cabinet is highly unlikely. Tagging of tools can work sucessfully on larger tools, but even so it is expensive both initially and ongoing, it can obstruct safe tool usage and be a FOD issue in itself, when a tag comes off.

So moving away from RFID, there is a solution which does not require any tool modification (ie: no tagging), covering exactly what is needed for aircraft tools and is the fastest system available - the kabTRAK Electronic Hand Tool Drawer Cabinet, part of the henchmanTRAK system. 

Electronic Tool Control of Portable Kits

People are led to believe that a portable kit with a reasonable number of tools that are tagged can be read through a scanner - this is only partly true. Unfortunately only about 80% of the tools tend to be read each time.

So apart from the RFID theory not working in practice, issuing and returning of portable toolkits is thought to be only possible by a visual check.

We have a solution for issuing/returning of portable kits that is 100% accurate, secure and can be unmanned - the portaTRAK toolkit scales. 

GSE & Special Kits & General Toolcrib Items

Consider some of the specialised tooling in your toolcrib. Some may be quite complex with attachments and fixtures etc., so that when it gets returned the storeman could hardly be expected to know if every last part of the tool was returned.

You cannot tag many of these intricate items and if you tried, how many tags do you put on to cover each part of the tool?

We have a simple yet safe solution for this, as well as a simple scan out/scan in system for bar-coded or tagged items - the cribTRAK barcode scanner. 

Centrally Accessible Overview

Ultimately all these tool movements of hand tools in rollcabs, portable toolkits, task specific kits, general tooling including GSE, can be monitored centrally through one system giving clear indication of the "tools out" status and which aircraft they are used on.

For more information visit our henchmanTRAK solution page or henchmanTRAK.com.

What is the real cost of a lost tool?

Regardless if you are working in the aerospace, construction, field service, automotive or mining industry, leaving your tools in an open area or in an area where multiple people have access to them throughout the day, can lead to misplaced or lost tools on the job site.

Not being able to find tools when you need them is more than just an inconvenience. The time spent looking for them eats into the productivity of your organisation.

Simple maths tells us that if you spent only ten minutes per workday searching for your tools, this would add up to a full 40-hour work week in a year.

…and this got us thinking. What is the actual cost of losing a tool?

The cost of downtime

We did some research:

1. According to a report from Ponemon Institute in 2016 the average cost of downtime is nearly $9,000 per minute. For small businesses, that number drops to the lower but still significant tune of $137 to $427 per minute.
2. In 2016, the average cost of downtime across all businesses was $260,000 per hour. That was a 60% jump from 2014. (source)
3. In some industries, the cost is considerably higher. In the automotive industry, downtime can cost up to $50,000 per minute, which equals $3 million per hour. (source)
4. Even so, the true cost of downtime is unknown. Consultants believe that 80% of industrial facilities are unable to accurately estimate their downtime. A common estimate is that factories lose anywhere from 5% to 20% of their productivity due to downtime. (source)
5. Human error causes 23% of unplanned downtime in manufacturing. That’s 2.5x higher than in other sectors. (source)
6. Faulty equipment is another common cause of downtime. A 2017 survey found that 70% of companies lack complete awareness of when equipment is due for maintenance or upgrade. (source)
7. The average cost of a downtime incident is about $17,000. (source)

As you can see, it’s difficult to come up with an exact figure as there are too many variables: duration of the downtime, number of people involved, reason for downtime, resources needed to fix the issue, lead time of new tools – to name a few!

We go into these in more detail below.

Factors that influence the cost of downtime

Firstly, of course you will have the replacement cost of the item. Depending on the brand and type of tool, this can be quite expensive in itself.

Then you have the administrative cost for the time spend looking for the tool. This may actually be higher than you realise. Firstly, there would be a physical search. You would need to retrace your steps, spend unnecessary time searching and then potentially be unsuccessful.

You may need the team to help search for the tool. This would result in time away from their application/production tasks and will create a roll-on effect whereby other jobs won’t get finished in time.

Depending on your workplace processes, you may need to file a report regarding the lost tool to superiors, wasting their time and using up valuable production time. Remember, time is money!

In the aerospace industry, you would need to consider the possibility of the cost of grounded aircraft or downtime in production. Should the lost tool end up in the engine or other critical parts of the aircraft (we don't like to think of it) there is always the possible risk of catastrophic or fatal equipment failure. Even just the need to repair a scratch caused by an insert bit might already cost thousands and take a considerable amount of time.

And what about the time spent raising a new PO, the time procurement spends on sourcing the tool, delivery of the item (which can be quite significant for imported tooling), the time spent for calibration if required and/or laser marking for identification purposes?

Lastly, what about the reputation of your company or team if the job or processes get delayed? This cost is immeasurable, not only resulting in loss of future work, but also the loss of potential new clients. Negative reviews are having more and more of an impact in today’s consumer market.

The potential costs are monumental, it just isn’t worth the risk! Thankfully, here at Henchman we have a tried and proven system to eliminate the problem.

So, what’s the solution?

The simplest solution is a Tool Control strategy. How this looks for your company will differ to the next (either Electronic or basic Visual Tool Control).

For the more budget conscious, Henchman have supplied visual tool control solutions for over 20 years:

• Store your tools in kits or boards that have two-coloured foam cut outs for tools making it very easy to visually identify missing items
• Laser mark tools so it is easy to identify which kit/foam layer they belong to
• Have a tool list with each kit which can act as a checklist
• Implement tool tagging procedures i.e. when a tool is taken, employees leave a tag with their initials/details beside the tool slot. This saves a lot of time tracking tools down
• Have strict documented procedures regarding the issue and return of tools

In addition to lost tools, broken or poorly serviced tooling can also impact greatly on productivity and downtime. We recommend investing in quality tooling from the outset, and having an accurate system to record Calibration/Servicing. Having reminders sent ahead of time to help you schedule the service will prevent downtime due to a broken or inaccurate tool.

Taking it a step further

Our Electronic Tool Control solutions HenchmanTRAK cut out the manual work and potential for human error by automating all of the above-mentioned steps. The HenchmanTRAK solution includes an entire family of systems to completely cover your needs which includes:

• Electronic automated toolboxes - kabTRAK
• Weight based system for managing portable tool kits - portaTRAK
• Smart locker systems to help with issuing and returning tool kits from an unattended remote site - lokkaTRAK
• A smartphone app with bluetooth locks to bring tool control right into the field
• A manual barcode scanning tool control system to help manage issuing and returning tools, consumables and GSE from the toolcrib - cribTRAK

Some of the benefits of going with electronic tool control over a simple tool tagging process are:

• More efficient and secure way to ensure each tool is issued to an engineer and returned correctly without skipping the process.
• Extra level of accountability with regards to issuing and returning "sets" and calibrated items.
• Automating the process will provide you with reporting capability.
• The ability to check the status of a toolbox remotely.
• Time stamp when a tool is issued, this could help in the case of a tool going missing to help in figuring out what specific task was being done at this time.
• Efficient way to mark tools as unserviceable and prevent them being used by another user.
• Will help in the case of tracing what aircraft a tool has been used on if found to be out of tolerance or not functioning correctly.
• Removing the need for tags which are a FOD issue in themselves.
• Reduce the risk of tool sharing as each user is required to return his own tools.
• Will enforce the tool control culture as you can’t skip the process. However the system is not in any way a hinderance to the speed in which a tool can be issued or returned.
• The system provides a way to set a "next calibration date" and doesn't allow the tool to be issued without an administrator confirming the calibration is complete and entering a new calibration date.
• In addition to saving money by preventing downtime, you’ll also save money by reducing time spent on administrative tasks like manually signing tools in/out and scheduling reminders for calibration. 

To sum it up

Nothing can completely prevent a misplaced tool or human error. But there are many things you can do to minimise the risk of material failure and lost equipment in order to prevent expensive downtime. Henchman specialises in coming up with the perfect system for your company, be it basic and straightforward, or detailed and electronic.

That cold beer is calling, so let us help you leave work on time, every night! 

Automated Tool Tracking with Electronic Tool Control Solution HenchmanTRAK

Who needs Automated Tool Control? 

Regardless if you are working in the aerospace, construction, field service, automotive or mining industry, leaving your tools in an open area or in an area where multiple people have access to them throughout the day, can lead to misplaced or lost tools on the job site.

Not being able to find tools when you need them is more than just an inconvenience. The time spent looking for them eats into the productivity of your organisation.

The simplest solution suitable for every kind of company is Visual Tool Control with two-coloured foam inlays - stationary, mobile and transportable sets, for everything from servicing atm machines and copiers, to maintaining and repairing mountainbikes, army vehicles, mining trucks, railway tracks and manufacturing facilities.

For Aerospace companies (including rotary and fixed wing), CASR Part 145 requires suitable accountability of tools/equipment, suitable procedures to avoid FOD and correct calibration management of tools/test equipment within specified date requirements. Meeting these requirements can be seen as creating a whole lot of extra work, red tape and delays when time is so precious. Is this how your company feels?

Why do you need Electronic Tool Control?

Electronic Tool Control reduces tool shrinkage, replacement cost and downtime due to lost tools. It offers centralized control of your essential hand and power tools. And it allows for customized badge access to storage units, provides an audit trail, and helps minimize the risk of FOD.

Why choose the kabTRAK storage cabinet by henchmanTRAK?

There are less than a handful of companies who produce anything along the lines of Automated Tool Control, and even from this handful most are unable to manage small items like 1/4 inch Drive Sockets, Screwdriver Bits, Cutting Tools, etc.

When the discussion of electronic tool control comes up many think RFID is the state-of-the-art solution, where in fact it is almost impossible to successfully tag all the required small tools. Successfully reading all tags when a kit may comprise of 1,000 plus tools in a cabinet is highly unlikely.

Tagging of tools can work sucessfully on larger tools, but even so it is expensive both initially and ongoing, it can obstruct safe tool usage and be a FOD issue in itself, when a tag comes off.

So, moving away from RFID, there is a solution which does not require any tool modification (ie: no tagging), covering exactly what is needed for aircraft tools and is the fastest system available - the henchmanTRAK system. 

Being the most comprehensive solution in the industry, you receive full accountability and will be able to know in real-time

• which tools are in use
• who is using them and when
• on which aircraft they are used
• if they are broken and need to be replaced
• if they need to be calibrated

Tools that are due for calibration or have been marked unservicable can not be removed from the toolkit and used on an aircraft, reducing the risk of damage to equipment, personal injury and FOD due to tool debris. 

New Automated Tool Control Solution Brochure

How is the henchmanTRAK Electronic Tool Control system different from other technologies and why is it the better choice?

This brochure shows you

• 9 distinct benefits of the kabTRAK system

• comparison of kabTRAK with other known tracking technologies

• possible cabinet sizes and drawer configurations

Download it here and contact us to book your personal zoom demonstration!

Meet Henchman at MRO Americas 2022 in Dallas, Texas

Henchman will participate in this years MRO Americas 2022 at the Kay Bailey Hutchison Convention Center in Dallas, Texas, USA. 

On booth 716 (see the latest floorplan here) we will be showcasing

• our Electronic Tool Control Solutions kabTRAK, portaTRAK and cribTRAK
• Toolkitting Solutions and Visual Tool Control using Shadow Foam
• Storage Solutions by Explorer Transit Cases
• Rugged Electronic Devices by Durabook

Contact us to arrange a meeting, secure one of the limited spots for your personal demonstration and receive the Show Specials.

Meet Henchman at the HAI Heli-Expo 2022 in Dallas, Texas

Henchman will participate in this years HAI Heli-Expo 2022 at the Kay Bailey Hutchison Convention Center in Dallas, Texas, USA. 

On booth 6423 (see the latest floorplan here) we will be showcasing

• our Electronic Tool Control Solution kabTRAK
• Toolkitting Solutions and Visual Tool Control using Shadow Foam
• Storage Solutions by Explorer Transit Cases
• Rugged Electronic Devices by Durabook

Contact us to arrange a meeting and secure one of the limited spots for your personal demonstration.

Choosing the right Borescope for your Application

There are numerous brands and models of Borescopes on the market, with a range of diameters and lengths. To help you choose the right Borescope for your application, we are explaining a few of the basic features.

What are Borescopes used for?

A Borescope is used to non-destructively inspect industrial systems and equipment for condition, manufactured parts for quality and security, and law enforcement for contraband, intelligence and safety.

Common inspections include internal viewing of:

• Turbine Engines
• Internal Combustion Engines
• Pipes
• Heat exchanger tubes
• Gear boxes
• Welds
• Foreign Object Retrieval
• Cast Parts
• Manufactured or machined parts

Borescopes can consist of

• Rigid rod or flexible tube to insert into the item under inspection
• Light source to illuminate the inside of the item under inspection
• Optical system that may consist of a relay lens system, rod lens system, fiber optic image guide a CCD or CMOS camera
• Eyepiece or Monitor to view the image

Rigid Borescopes

If your entry path is straight, a rigid borescope delivers excellent image quality and can be more durable and cost-efficient than other types of borescopes, such as fibreoptic or video borescopes.

Rigid Borescopes are used to inspect machine parts, welded tubes, some castings, especially deep narrow bores.

Rigid Borescopes use traditional, glass optics to relay the image. The heart of a rigid borescope design is the relay lens system.

Traditional solutions, like the Hopkins design, use many expensive micro-lenses and optical glass rods. The elegant simplicity of Gradient Lens Corporation’s patented endoGRINs® design make lens manufacturing and assembly easier and less costly, resulting in excellent optical quality at a much lower cost. The endoGRINs® gradient index lenses are the core technology of Hawkeye® Pro and Classic Rigid Borescopes.

Flexible Fibreoptic Borescopes

Flexible Borescopes are the best choice for a curved entry path and complex castings, such as engine blocks and heads, bent tubes, fuel reels and hydraulic lines.

Fibreoptic borescopes use optical glass fibres to relay the image. The resolution depends on the number of fibres and their diameter. Each fibre forms a pixel in the final image. If your entry path is not straight, fibreoptic borescopes have the advantages of flexibility and articulation.

Video Borescopes

Video Borescopes are used for reliable and critical inspection of aircraft diesel and turbine engines without costly and time-consuming engine teardown, especially but not limited to Aircraft Maintenance and the Aviation Industry.

Power generation teams use Video Borescopes to inspect generators, heat exchangers, combustion chambers and turbine plates.

Manufacturers of castings and other complex parts inspect for voids, sand, flash, and other defects even inside complex parts.

When compared with any other type of borescope, video borescopes deliver the best combination of image quality and convenience. Videoscopes transmit light through the objective lens to miniature video cameras, which then convey the image to a portable handheld monitor or laptop and desktop computers. When portability, still and video image capture, and image storage and documentation are key factors, a videoscope is the right choice.

Direction-of-View (DOV)

Hawkeye Pro and Classic Rigid Borescopes see straight-ahead (0°) and sideways (90°) with a mirror tube that slides over the borescope tube, making them two borescopes in one. The Hawkeye Pro Slim Rigid also offers a special dedicated 30° Direction of View scope using a prism.

The mirror tube rotates the view over a full 360°, using the knurled knob. Our new mirrors are robust and durable for easy cleaning.

Field-of-View (FOV)

Most inspection situations need a “normal” objective lens (like a typical camera) with an angle of about 40°.

Wider lenses see more, but at a lower magnification, giving less detail. Magnification increases as the borescope approaches the subject, unlike a microscope objective, which gives a fixed magnification at one object distance.

Hawkeye® Borescopes

Hawkeye® offers over 80 models of either rigid, flexible or video borescopes with diameters between 0.5mm to 8mm and length between 2 inch up to 20 feet. Get the best quality for the most cost-effective solution!

Hawkeye® Rigid Borescopes:

Compared to other types of borescopes, Hawkeye® Rigid Borescopes have better image quality and are more durable and less expensive than flexible scopes. Hawkeye® Pro Rigid Borescopes have DOV’s of 0°, 30°, and 90°.

Hawkeye® Micro Flex & Semi-Rigid Borescopes:

Hawkeye® Pro MicroFlex Semi-Rigid and Flexible Borescopes offer diameters as small as 0.5 mm, and a 10,000 or 30,000 fiber image bundle, all in “bendable,” semi-rigid, Nitinol or polymide sheath.

Hawkeye® Flexible Borescopes:

The Hawkeye® Pro, Classic, or Blue Flexible Borescope offer 0-way, 2-way, or 4-way articulation, up to 25,000 pixel image resolution, and flexible, durable, tungsten sheathing. Hawkeye® Flexible Borescopes are the finest fiberscopes on the market.

Hawkeye® Video Borescopes:

The Hawkeye® V3 HD Video Borescopes represent the next generation of fully portable, articulating, videoscopes. The innovative custom engineered image processor allows users to view or capture bright, crisp, clear images with lifelike colours. The servo driven articulation allows users to easily navigate even the toughest to access inspections.

Source: Hawkeye Borescopes by Gradient Lens

Choosing the right tough Tablet for our HenchmanTRAK system

We were looking for a rugged tablet, that was readable in sunlight, temperature resistant, customised to our needs, yet affordable. What convinced us that a DURABOOK rugged tablet was the right choice?

In 2015, we were looking for a rugged touch-controlled display for the very first prototype of our Electronic Tool Control System HenchmanTRAK.

We needed a tablet that 

• had all the right connections to be permanently installed on the HenchmanTRAK units.
• was able to withstand the high temperatures of an Australian summer in the Northern Territory as well as the low temperatures of a winter in Victoria.
• didn't have a camera, so that it could be used by the Australian Defence.
• was readable in bright sunlight.

We quickly realised that we'd need a cutomised solution, but couldn't find a manufacturer that was able to supply it at an affordable price. That's when we discovered DURABOOK at a tradeshow in Brisbane, Australia. Convinced about their product features and certifications, we ordered a test model customised to our requirements.

“We found the DURABOOK tablets to be highly reliable units and found DURABOOK to be an extremely professional company.” 
Alisdair Chambers, CEO

Henchman has been supplying a customised version of the DURABOOK R11 tablet on our kabTRAK roll cabinets and portaTRAK toolkit scales ever since.

Read the full Case Study here: Case Study: DURABOOK Rugged Tablets for the HenchmanTRAK system (PDF, 247KB)

Why choose DURABOOK?

There are a few competitors in the market offering rugged or ruggedised tablets and laptops. While the basic specifications and certifications might be quite similar, Durabook has a few advantages. Having their own production, they are able to offer new technologies, upgrades and custom-build models in a lot shorter amount of time than their competitors.

For consumers: Durabook standard models like the R11 tablet or S14I laptop are certified to all necessary standards, are waterproof, dustproof, shockproof and dropproof to a certain height. Therefore making them a good choice for your every day application at an affordable price.

For companies: Durabook has the ability to custom-build rugged tablets and laptops to your specific requirements even in small numbers. High-end models like the Z14I laptop or U11I tablet (now also available with a detachable keyboard) are certified to withstand even the harshest environments, making them suitable for long-term usage in the field. 

What is different about DURABOOK?

State-of-the-art Technology: Durabook offers latest Intel® generation processors, packed with great performance and visuals into a compact form. Plus, the high-speed data transmission capability of newest Intel® Dual Band Wireless and Bluetooth® V5.0 means smooth, congestion-free processing at all times.

Compact Built for all Purposes: Compact design and rich range of built-in connectivity options to maximize the efficiency for those who work in extreme conditions. Durabook redefines what a rugged mobile device should be and make its products the world’s thinnest and lightest in its class.

DynaVue® – Detail at a Glance: Durabook’s proprietary DynaVue® technology offers the highest contrast ratio, which helps to eliminate internal reflections that enhance viewing clarity even from different angles, and in bright sunshine or low light conditions.
The 10-point capacitive multi-touch panel has four Touch Modes (Glove, Stylus, Water, Finger), optimizing use of the device for both indoor and outdoor applications.

Built for all Environments: With invincible mechanical design and rigorous component selection, Durabook products adapt to any environments flawlessly. They are MIL-STD-810G, MIL-STD-461F certified, ANSI 12.12.01 C1D2 certified, and IP rated, assuring shock, drop and vibration protection. Experience peak performance in dust, humidity and extreme temperatures – whether in freezing cold -30°C or hot temperatures of +60°C - which makes it more rugged than ever.

Faster Lead Time and flexible Customization: Durabook products are built with modular design for easy addition of feature. For more extensive customized products, we provide a rich pool of design collaterals. From boards, displays to chassis, we can build to your need quickly and economically. They are committed to excellent service, offering fast delivery time, flexible customization service and a complete warranty package to ensure user satisfaction.

Hardware specially designed for your industry

Manufacturing & Maintenance: Effective mobile devices to optimize your productivity - Empower your workforce with flexible, efficient devices that maximize productivity. Durabook tablets and laptops are packed with features that get you to work faster and more efficient. Working without limits.

Transportation & Logistics: Maximize worker utilization and improve logistics performance - Durabook innovative product lineup ensures your operations are running smoothly. By improving agility and productivity through real-time access into your supply chain processes, your workforce can fulfill their duties even more efficiently.

Field Service & Mining: Rugged Devices designed to empower you on the Front Line - Dependable technology is essential to produce and deliver exceptional projects under any deadline. Get the necessary Durabook device you need that improve work process, security and functionality, no matter where your workplace is.

Public Safety: Cutting-edge mobile devices to provide greater efficiency - Handy and efficient mobile devices support your workforce and keep data and everyone safe in real time. Durabook devices are assisting your organization to improve the workflow and make things easier, helping you protect and serve the public.

Government & Defence: Computing Devices for Operational Success - Durabook fully rugged products are built to withstand extreme conditions and meet the increased demands of field use. Certified for military standards, Durabook devices support you to meet your missions and protect your most important asset: data.

A Guide to Intrinsically Safe Aircraft Maintenance Equipment

The aviation industry is rightly consumed with safety and accident prevention; this includes when the planes are grounded. MROs are working with aircraft that often contain fuel and need maintenance of electrical parts - a dangerous combination. These conditions require MROs to use tools which are classified as "intrinsically safe", but what does this mean?

What is Intrinsic Safety?

The aviation industry is rightly consumed with safety and accident prevention; this includes when the planes are grounded.  MROs are working with aircraft that often contain fuel and need maintenance of electrical parts – a dangerous combination. These conditions require MROs to use tools which are classified as ‘intrinsically safe’, but what does this mean? 

This article explains the term ‘intrinsically safe’ in the context of aerospace and the MRO environment. It will also explain the obligations upon MROs to use intrinsically safe equipment, and the potential consequences if incorrect equipment is used. 

Your working environment implies risk from fire

Fuel, oxygen and a source of ignition must present in order for fire or an explosion to occur. Engineers working on commissioned – and therefore fuelled – aircraft are in an environment which is at inherent risk from fire.

What does the term ‘Intrinsically Safe’ mean within the aviation industry?

The term Intrinsically Safe describes equipment “which is incapable of releasing sufficient electrical or thermal energy under normal or abnormal conditions which may cause ignition of a specific hazardous atmospheric mixture in its most easily ignited concentration“

Equipment used near aircraft (i.e. in hangars) are subject to increased safety standards to prevent the possibility of fire and explosions. These locations are deemed ‘hazardous areas’ when there is the possibility of fuel or fumes to be present. This includes all areas along the hangar floor.

How is equipment designed to meet the ATEX/Intrinsic Safety Standards?

The electronic circuitry is designed to limit the electrical or thermal energy, by several methods:

• Current limiting
• Creating fused isolated areas
• Using overvoltage protection
• Minimising the amount of stored energy
• Reducing the amount of surface static on its enclosure.

When should Intrinsically Safe equipment be used?

For MROs working in aviation, the decision-making regarding the necessary equipment has been done for you.  The hazardous zones are clearly defined, and only equipment classified for use within these zones should be used.

The Boeing Company specify the use of Intrinsically Safe equipment within the fuel vapour zones around airplanes and on fuelled aircraft. All equipment must be suitably certified for use within these zones to avoid the risk of spark ignition and the potential for catastrophic damage to personnel.

The below diagram displays the hazardous zones as determined by The Boeing Company. 

Is Intrinsically Safe equipment more expensive than non-certified equipment?

In a word – yes.  Electronic Equipment designed to operate in hazardous areas must comply to the ATEX Directive and must therefore meet the Harmonised Standards within this. In the case of an intrinsically safe design, costs will incur because of the additional testing requirement by an external notifying body. A company cannot self-certify because of the equipment’s intended use – in this case, Hazardous environments.

Although the components within the equipment are generally cost-neutral compared to standard equipment, the costs of the R&D programme and the process of obtaining the certification incur additional costs.

What are the benefits of using Intrinsically Safe equipment rather than purging aircraft of fuel?

Besides ensuring compliance with the AMM (Aircraft Maintenance Manual), there are several other benefits of using explosion-proof equipment for busy MROs:

• The number one point and of key importance is the fact that it helps to ensure a safe work environment and protects those nearby from explosion risks.
• Maintenance and diagnostic work can be performed without shutting down production and ventilating the working area
• Insurance premiums may be lower as a result of the risk reduction.

What are the different area classifications?

• Zone 0: An area in which an explosive gas atmosphere is present continuously or for long periods of time.
• Zone 1: An area in which an explosive gas atmosphere is likely to occur under normal operating conditions.
• Zone 2: An area in which an explosive gas atmosphere is not likely to occur under normal operating conditions.
• Non-hazardous: An area with very low risk of release of explosive or flammable gas; such as the propellant in an aerosol spray in an office.

For more information visit the MK Test website and read about the ExLRT Intrinsically Safe Loop and Joint Tester.

Complete Workstation Setup for Electronics Manufacturing

We not only work with you to design the perfect Workstation setup, as a Single-Source Supplier we can also supply ESD and Soldering Equipment, Fume Extraction Systems and Consumables.

Leading ergonomic Workstation Design
Many of our projects are designed for our customers unique applications. It starts with a call or an email to our office. Off your freehand sketch we will return our technical drawings and a quote with your product requirements - incorporating ergonomics, aesthetics, strength and modularity.

Customized for the Application and your Operator
The purpose of a workstation determines its basic requirements and accessories. The needs and requirements may change considerably from one employee to another, but we understand that no two people are like. When a workstation is equipped for and adjusted to an operators needs, each phase of the production process can be completed accurately without delay and discomfort.

Organisation is a sign of Efficiency
Necessary tools and materials must be at the workers fingertips in order to be efficient. There is no time lost in looking for parts or tools if the workplace is properly organized for the work performed there. A tool kept in its own place stays in good condition for a long time. These workplace solutions make it easy to implement lean manufacturing such as 5S (sort-set-sustain-shine-standardize).

Ergonomics improve Satisfaction and Productivity
The main objective of ergonomic design is ensuring the employees health, increasing work satisfaction and improving individual productivity. This series workstations ultimate goal is to ensure a relaxed working position where the work movements can follow the individual’s natural way of moving. Properly designed and configured workstations are an important element of a lean manufacturing system and can have an impact on reducing waste. Workstations must be easy to reconfigure to handle small batch sizes when needed.

We not only work with you to design the perfect Workstation setup, as a Single-Source Supplier we can also supply

• ESD Chairs
• Bench Matting
• Personal Grounding
• ESD Control
• Conductive Equipment
• Fume Extraction
• All kinds of Tools
• Soldering Equipment and Consumables
• ... and much more.

Contact us with your specific requirements.

Mining Tools & Services Brochure

In this new brochure you can read all about our capabilities, tools and services for the Mining & Energy sector.

See the PDF here: Mining Tools & Services (PDF 5.8MB)

The contents include our range of:

• Toolkitting - for tools in all shapes and sizes
• Visual and Electronic Tool Control
• Toolcrib & Container Setup
• Repair & Calibration Services
• Premium Industrial Hand Tools (incl. VDE and Tethered Tools)
• Power Tools
• Torque Fastening Tools
• Fluke Test Equipment
• Break Washers
• Personal Protective Equipment (PPE) incl. ArcFlash
• Consumables