Flight Design Completed First Flight of new C4

Four Seat General Aviation Entry Successfully Takes to the Air

Kamenz, GERMANY / 14 April 2015 — Last fall, Flight Design GmbH, manufacturer of the popular CT-series of Light-Sport Aircraft, promised to fly its new, certified four seater called C4 by the opening of the Aero Friedrichshafen show. On Friday, April 9th, the development team achieved their goal. The weekend was spent reviewing initial results (see below) and preparing to set up at the event that start April 15th.

“The C4 really performed as expected,” reported Tom Peghiny, President of Flight Design USA, importer of the German company’s products and test flight director for the C4 development. Peghiny flew alongside the C4 non-conforming prototype. “It appeared and test pilot Damian Hischier confirmed that the C4 is stable about all axes.”

Hischier also reported, “The spiral stability of C4 is good and its directional stability is good.” While noting that engine operating temperatures were acceptable he acknowledged that further work may be necessary for operations in the hottest climates. “But don’t change a thing aerodynamically,” Hischier enthused! Engine temperatures will be remedied primarily with cowl changes focused on cooling, yet Flight Design is pleased with the Continental IO-360-AF engine that performed very well.

“Flight Design engineers can work on reducing some friction in the controls,” Hischier noted, “but leave the rest alone.” Most prototype airplanes go through refinements after the initial flight verifications even while most of the group working to achieve the first flight were pleased that the new airplane performed so well.

“We observed the C4 accelerate away from the C-172 chase plane during simulated approaches to landing and in simulated go-arounds,” commented Peghiny, observing from the Cessna.
“I could also see that during the 30 degree bank turns the test pilot needed no control correction and he reported that pitch forces were light,” added Peghiny. “The plane appeared to be on rails, it looked very stable. Damian said he was comfortable getting close to us for the photos and videos shot during the maiden flight.” On board avionics are supplied by Garmin with the G3X Touch augmented with TSO analog instruments. Garmin has become a vital partner to Flight Design as C4 moves forward.

“Very few first flights proceed through the entire test card,” explained flight director Peghiny. “Yet we completed all of the points permitted under the EASA-established Flight Conditions as specified in our initial Permit to Fly authorization.”

“We are all exceedingly pleased to have reached this benchmark as forecast a few months back,” said Christian Wenger, a Flight Design corporate board member and procurement manager for the German manufacturer. “This is going to make for a very enjoyable show for us.” Wenger spoke to early arriving media reporters as he lead the team positioning the test article C4 at the front of the company’s display in Hall B-1 of the Aero Friedrichshafen show.

“Our whole team put in long hours and formed a cohesive team as they rallied behind the C4 first flight effort,” said Matthias Betsch, CEO of Flight Design. “All team members are very pleased with the results of the development effort.” Flight Design has been at work on the C4 project since 2011.

“In coming days and weeks, we will add more details about this project,” added Betsch. “For now, part of our team is working to prepare the C4 for display at Aero while engineers like Technical Director Oliver Reinhardt remain at headquarters preparing the next steps in the development project.

“We will release more data and will provide more detail on the C4 development schedule after we get through Aero and Sun ‘n Fun,” Peghiny said. The two important airshows, one in Europe and one in the USA, run nearly back to back starting Wednesday April 15th, 2015. “Meanwhile, we are very pleased to show the actual plane at Aero.” The prototype will immediately continue development flight evaluations and will not be seen in the USA until later this year.

For Preliminary flight data download full press release.

Service Bulletins BRS, Dynon, Rotax and Revisions

Flight Design has just released a Service Bulletin for the inspection the BRS handle bracket for the absence of cracks in the bend radius at the base plate.

is applicable to all CTSW, CTSW-LSA and CT Supralight with Airframe Emergency Parachute System BRS 1050 and 1350 installed, from S/N 05-01-01 / D-05-01-01 and E-09-02-11 without country limitation.

periodic inspection of float buoyancy for 912/914 equipped CTLS/CTsw and MC aircraft



SAFETY ALERT- Installation Verification of BRS Pickup Collar

A safety Alert applicable to All aircrafts with Airframe Emergency Parachute System BRS 1350 HS installed, and with S/N up to F-13-09-04, C-11-11-02,A-12-04-33, included.


Please refer to This Alert


Aircraft with higher S/N are not affected.


Flight Design West Serves Customers in Three Locations

South Woodstock, CONN. / October 21, 2014 — Flight Design USA has maintained the largest fleet Light-Sport Aircraft for the entire ten year history by always striving for the finest customer service in the sector. A clear reason for their success is a network of qualified dealers and distributors with a similar commitment. One of those is Flight Design West, an exhibitor at the 2014 Flying Aviation Expo.

            Flight Design West is led by president Kenny Scherado, the founder of Lone Mountain Aviation, a western company based at the Northwest property of the North Las Vegas Airport in Las Vegas, Nevada. In addition to Lone Mountain, Flight Design West also lists dealers as Sonoma Jet Center in Northern California and Copper City Aviation in Bisbee, Arizona.

            Supporting Flight Design West, Scherado’s Lone Mountain operation is an authorized service center for Cirrus, Cessna, Piper, and Mooney. They provide an avionics repair station and offer workshops for composite repair, sheet metal, plus general maintenance. The company is one of the few Certified Repair Stations in the country with a Class 1 Unlimited Composite Repair Rating. As Flight Design’s CTLSi and earlier models are built of 98% carbon fiber constructions Flight Design West makes good use of Lone Mountain’s expertise with such materials.  All operations are conducted under approval as FAA 145 Repair Station L9OR473Y.

            “We are very pleased to be supported in western United States by Flight Design West and their maintenance facilities at Lone Mountain Aviation,” said Tom Peghiny, president of Flight Design USA. “Kenny Scherado has been a great partner to us and brings long experience to the task.”

            An Air Force veteran, Scherado has more than 45 years of experience in general aviation and major airlines. Kenny is an A&P with Inspection Authorization, a Designated Airworthiness Representative for FAA, and an instrument rated private pilot. Scherado created Lone Mountain Aviation in 1982.

            “With 23,000 square feet of hangar space, sophisticated tooling, and continuous factory authorized training, our technicians are well equipped to provide superior quality service to customers,” said Scherado. “We promise to keep our customers flying by maintaining aircraft on their budget, reducing down time, and delivering a safe, reliable and quality product.”

            At the Flying Aviation Expo, Flight Design West is displaying their CTLSi for visitors to examine. The model is part of the CT series from Flight Design in Germany that has continuously remained the top-ranked Light-Sport Aircraft for more than ten years. CTLSi is a wide cabin Light-Sport Aircraft superbly equipped with an all-digital instrument panel, the fuel injected Rotax 912 iS engine, and a BRS airframe parachute system.


            Flight Design is a 25-year-old manufacturer based in Germany. The company remains the worldwide Light-Sport Aircraft market leader thanks to its popular CT series of aircraft. More than 1,800 of these aircraft are flying in 39 countries. One of the first aircraft certified under ASTM International standards in 2005, the CT (“composite technology”) remains the top-selling LSA in America through eight consecutive years. Flight Design sold the first LSA to India and was the first LSA to earn Chinese Type Design Approval. Three times a CT has been flown around the world. In 2011, the German company unveiled its C4 four seat aircraft based on the CT technology.



Flight Design C4 Aircraft as First Target Application,
System Available to Other Airframe Manufacturers



Friedrichshafen, GERMANY (AERO Fair)  / 10 April 2014 — With a project starting date in Summer 2013, the German Ministry of Economic Affairs has granted funding for a research project that aims at development of a modular “SafetyBox” cabin safety system for light aircraft. The new system will provide a safety cage around the occupants of an aircraft, whose functionality builds upon an integrated consideration of several elements, namely intelligently designed and located crash absorber elements, stiff cabin structure with dedicated load paths for the majority of crash scenarios, seat installation and restraint systems. This is significantly supported by crash-optimized ergonomic designs and enhanced fire protection concepts.

The concept goes significantly beyond current aircraft designs, where the certification requirements plainly ask for consideration of certain crash accelerations to the seat and restraint Read the rest of this entry »

Flight Design Globalization

Flight Design Supports Local Licence Productions for Asia-Pacific and America


Aero Friedrichshafen, GERMANY / 10 April 2014 — For many years, Flight Design has continuously reached out to new markets to ensure global availability and support of Flight Design products. As the next logical step, Flight Design is now providing local production capacities for the major market segments. With this strategy, Flight Design significantly improves availability of the products, reducing production lead times and ensures continued affordable aircraft prices.

The first local production will serve the Asia-Pacific markets with the Flight Design products CTLS, MC and C4. For more than one year Flight Design has been training staff at the Xiamen, China, facility of AeroJones. The China based and Taiwanese owned company is linked through the owner of GSEO, a company producing optical lens systems for IT systems with a total of 20,000 employees. “Over the years, we have had contacts with many different interested parties, and spent a lot of time investigating the possibilities in China”, Matthias Betsch, CEO of Flight Design, says. “From the very first moment when we met with Mr. Jones Chen, we understood that GSEO is the ideal partner to set up a highly efficient aircraft production with highest quality.” Training and factory setup are highly advanced, first assembly of a China produced aircraft is expected in late Summer 2014. This first aircraft will be the basis to extend the existing production approvals of Flight Design to this location, leading to first customer deliveries with the beginning of 2015. “The CTLS is the first aircraft that has achieved Chinese Type Design approval as LSA aircraft,” Betsch continues.  “Adding local production will secure market leadership for this product also in this part of the world.”

The second step of going global is linked to the USA Importer of Flight Design Products, Tom Peghiny. As many key components of the upcoming four-seat aircraft “C4” of Flight Design are of US- origin, it was a natural step to develop the concept for a final assembly line of this new product in USA. With Flight Design Americas, Peghiny is setting up an all-new facility in Newport, Vermont, where airframes produced by Flight Design Germany within its Ukraine facility will be completed and directly delivered to customers in all countries of North and South America. “We are thrilled by the possibilities we get out of this arrangement”, Tom Peghiny comments. “Our very successful partnership with Flight Design on the LSA market over many years has developed such an efficient way of working together, that the establishment of Flight Design Americas was truly a logic step, that will add significant value to all customers on the American continents.” With Continental for the engines, Garmin for the Avionics, two of the key systems of the all-new aircraft are produced with USA and can be supplied much more efficiently to the new facility.



Flight Design is a 26-year-old manufacturer based in Germany. The company remains the worldwide Light-Sport Aircraft market leader thanks to its popular CT series of aircraft. More than 1,800 of these aircraft are flying in 42 countries. One of the first aircraft certified under ASTM International standards in 2005, the CT (“composite technology”) remains the top-selling LSA in America and many other countries through many consecutive years. Flight Design sold the first LSA to India and was the first LSA to earn Chinese Type Design Approval. Three times a CT has been flown around the world. With the development of its C4 four seat aircraft based on the CT technology, Flight Design is consequently enhancing its product portfolio into the next larger segment.

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Flight Design Selects Avionic System for its 250.000 USD Four-Seat Aircraft
Aero Friedrichshafen, GERMANY / 10 April 2014 – The Flight Design C4 program is continuously moving ahead and Flight Design is pleased to announce the last major component and supplier to be selected for the all-new four-seat aircraft. The Avionics suite for the 250.000 USD composite aircraft will be provided by Garmin, and is named the Flight Design Vision Touch by Garmin.
With the decision of Garmin, Flight Design confirms two major features that will help to make the C4 aircraft popular and successful. First, the newly developed system with two 10,6 inch brilliant glass displays of the new Garmin G3X |Touch” series offers unique state-of-the-art performance and outstanding utility to the pilots. Second, the decision to use a system that does not have a TSO approval on its own, but will be certified together with the airframe, allows for a significantly lower price point with much greater flexibility for future system enhancements and upgrades.
The C4 will debut several of the new possibilities that go along with the CS-23 / Part 23 rewrite, driven by the FAA and well on the way to adoption by all major Aviation Authorities. One of these possibilities is the use of alternatively approved avionics in such an aircraft when certifying the Avionics as part of the airframe. “Affordable new technology is the goal of the (FAA) Part 23 rewrite,” said Tom Peghiny, president of Flight Design USA. “That’s what we’re doing with the C4.
The use of non-TSO avionics raises the certification burden for the airframe manufacturer, but in the end saves a significant amount of cost while offering much more up-to-date technology.”
The Flight Design Vision Touch suite by Garmin provides two widescreens capable of synthetic vision, combined with a Garmin GTN 750 GPS-Nav-Com, Garmin GNC 255 Nav/Com, Garmin GMC 305 autopilot, and a Garmin GMA 350 audio panel. Primary flight information is enhanced by an independent RC Allen solid-state attitude indicator, directional gyro, as well as analog airspeed and altitude indication. 
The C4 development process is well under way with the continued production of the first flying prototype and the successful completion of the first series of structural load tests to support prototype operation. First flight is expected for summer this year, leading fast to the production of the first conforming prototypes to directly support certification. Certification is anticipated before middle of 2015.

Sun n Fun display

Flight Design plans include a full interior mock up of the C4 with the debut of a special Garmin avionics suite, the exterior mock up of the C4 and some exciting new Dynon equipment changes for the CTLSi.

We plan to conduct demos at the renovated and convenient Paradise City strip on site.

The Flight Design Booth is MD-27C located on the main manufacturers display at show central. Sun n Fun will be a solid start for an exciting year. The show runs from April 1-6 at KLAL


                                                                                                                                                                                                         Roomy New Facility Brings Together CTLS and Four Seat C4

Kamenz, GERMANY / 1 February 2014 — German Light-Sport Aircraft market leader Flight Design GmbH, also developer of larger aircraft like the four-seat C4, has expanded its operation to Kamenz, Germany and is now fully installed in spacious new quarters .

We are now occupying a big hangar plus a smaller structure used for pre-delivery flight testing. The new quarters are located at a former military base, 100 miles (160 km) south of Berlin with a 3,000 foot (1.000 m) paved runway,” noted Flight Design GmbH board member and company director, Christian Wenger. “We are able to use the large hangar to stage finished aircraft after routine production and flight testing is complete. Once approved by engineers, Light-Sport Aircraft and European Ultralight aircraft are prepared for shipment to dealers in other countries or for pick up by European dealers and customers.” Departments include work shops for avionics and engine installation, composite repairs and painting, plus final assembly after receiving major components from another division outside Germany. The Kamenz facility takes over all responsibilities of Flight Design’s former Stuttgart center to further streamline operations, optimize costs, and reduce complexity in the manufacturing and distribution of CTLS Light-Sport Aircraft.hangar-1-south-view-2-c

Inside the main building referred to as “Hangar 1” the company has ample office space for the EASA Part 21J Design Organization (including engineering and flight test) and EASA Part 21G Production Organization (including quality management staff and Production Management), for which approval is expected shortly. The upper floor on the northeast side is occupied by Finance & Administration, including meeting room and Directors office.hangar-1-north-view-c

“Activity is high,” Wenger continued. “We hired additional staff since late 2013 at our Kamenz location and we have added mechanics and technical personnel recently.” Wenger added that the larger facility and additional workers are helping to reduce back log as the company adjusts to higher demand following slower years during the global recession. The company had previously done flight testing at a smaller remote facility but has also moved this function to the larger airport facility.

“Presently we employ 18 people in Kamenz,” Wenger said, “with 10 of them working on aircraft completion and delivery. The German company continues to own and operate a large component fabrication facility in Ukraine, which is constantly monitored and supervised by leading Flight Design personnel, including the Directors.hangar-1-north-view-1-c

“Flight Design GmbH has been working diligently to increase production as orders rose throughout 2013,” noted Tom Peghiny president of Flight Design USA, the official representative for the German aircraft maker. “Company directors reduced staff and inventories during the economic downturn, but it now appears we have solidly turned the corner. We are pleased to note the new Kamenz facility has already increased efficiency and quality by a significant margin.”


Flight Design is a 25-year-old manufacturer based in Germany. The company remains the worldwide Light-Sport Aircraft market leader thanks to its popular CT series of aircraft. More than 1,800 of these aircraft are flying in 39 countries. One of the first aircraft certified under ASTM International standards in 2005, the CT (“composite technology”) remains the top-selling LSA in America through eight consecutive years. Flight Design sold the first LSA to India and was the first LSA to earn Chinese Type Design Approval. Three times a CT has been flown around the world. In 2011, the German company unveiled its C4 four seat aircraft based on the CT technology.

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FLIGHT DESIGN USA CONTACT:  John Gilmore, national sales manager of Flight Design USA at 612-759-2252 (email: jgilmore@flightdesignusa.com) or Flight Design USA in Connecticut at 860-963-7272


PHOTOS — High resolution photos of all Flight Design aircraft and other images can be downloaded at: http://FlightDesignUSA.com/media


Service Alert SA SA-ASTM-CTLS-04 Rotax 912iS (CTLSi Aircraft)

Flight Design has issued a  Mandatory Safety Alert (SA) issued December 19, 2013.  For Fuel Injected CTLSi aircraft.

This Safety Alert requires you to determine, by reference to engine type – Rotax 912iS, if your aircraft has been affected. Detailed information is available on the Flight Design webpage: http://www.flightdesign.com/index.php?page=service, as contained in SA-ASTM-CTLS-04/ SA-LTUL-CTLS-04 documents. This Flight Design SA requires verification of ground wiring Lane A connection to regulator of Lane A prior to next flight. This verification may be done by the Owner / Operator. If your aircraft is not affected, this must be noted in the logbook that the SA is complied with by non-affectivity due to presence of non-conformance. For affected aircrafts, full compliance with SA-ASTM-CTLS-04/ SA-LTUL-CTLS-04 must be carried out and so noted in the logbook.

If you have a CTLSi and did not get an alert Email Please  go to our Contact us to be sure we have the correct email address.

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