Emergency in-flight egress opening for general aviation aircraft

An emergency in-flight egress system was installed in a light general aviation airplane. The airplane had no provision for egress on the left side. To avoid a major structural redesign for a mechanical door, an add on 11.2 kg (24.6 lb) pyrotechnic-actuated system was developed to create an opening in the existing structure. The skin of the airplane was explosively severed around the side window, across a central stringer, and down to the floor, creating an opening of approximately 76 by 76 cm. The severed panel was jettisoned at an initial velocity of approximately 13.7 m/sec. System development included a total of 68 explosive severance tests on aluminum material using small samples, small and full scale flat panel aircraft structural mockups, and an actual aircraft fuselage. These tests proved explosive sizing/severance margins, explosive initiation, explosive product containment, and system dynamics. This technology is applicable to any aircraft of similar construction.