What does it take to develop a revolutionary new product like the Air7? It starts—quite naturally—with a madcap idea to solve an industry-wide problem. Otherwise known as a ‘what if’ moment.
But it’s easier said than done to translate a brilliant idea into business reality, no matter how worthwhile pursuing.
And that was certainly the case with VRR’s inflatable AKE.
It’s an interesting story, so we’ve decided to reveal the lengths we’ve had to go to in order to create the Air7. In this article, we’ll reminisce about the beginnings of an idea, the generation of a concept, and the delivery of a prototype.
The idea of using inflatable panels to build a foldable and stackable container was an idea we’d been toying with for some months. However, each time we explored it in depth, the idea was dismissed as exciting but unfeasible.
In the meantime, we continued our work on mechanical collapsible containers in an effort to solve the global imbalance of Unit Load Devices (ULDs). Our solution seemed to be working quite well for main-deck containers, and the initial response from the market was positive. Still, finding a solution for the ever-popular lower-deck AKEs was proving much more difficult.
Lower-deck containers, which are shorter than main-deck containers and follow well-established contours, make up the majority of the global ULD fleet. However, their specific weight, handling and durability requirements were sticking points for the mechanical collapsible version.
And so, the notion of inflatable panels wasn’t forgotten, unwilling to file it under “ideas that didn’t make the cut”. The breakthrough came when we browsed through a product folder containing a variety of SUP boards and inflatable boats. The material these products are built from are strong, flexible and durable—perfect for collapsible containers.
It dawned on us that the ‘what if’ moment may not be as crazy as we thought. Full of renewed enthusiasm, we entered a new phase: research.
Research into a foldable/stackable AKE container began by assembling an internal R&D team to see if the theoretical would work in practice. As with any research project, we needed to find a principle solution for the main design challenge and then prove its functionality. We needed a Proof of Principle. A pre-prototype of the final product, if you like.
The main design challenge was this: to create a folding concept that is easy to use, simple to set up and folds in a controlled way every time, without making concessions to the AKE’s weight, robustness, strength or safety.
Understanding the true impact of the challenge and the project’s main drivers and boundary conditions is essential at this stage. The non-critical details could be shelved until later. So, the team broke down the main challenge into numerous sub-challenges:
This daunting list of challenges certainly put our designers and engineers through their paces. In fact, it took these talented people almost a whole year to tackle each one and produce a Proof of Principal.
But it was worth all the effort.
In March 2019, we launched our concept—the first of its kind in the world—during the 13th World Cargo Symposium in Singapore. We called the concept the Air5 because, when it’s folded, it can be stacked five high in a plane’s hold or in a warehouse.
Audiences watched with amazement as the Air5 inflated automatically into its final shape in just 30 seconds. Collapsing the container didn’t take much longer. Only two minutes (and two people) to release the air and fold in the sides.
The response was all that we could have hoped for. Our inflatable container was seen as a potential solution to reducing the ULD imbalance around the globe. The message was loud and clear: we were backing a winner.
The next stage in the project was to develop a prototype that would prove the concept’s usability in the real world. The main aim was to simplify the concept and reduce its cost and weight. To do so, the R&D team had to plough through another long list of challenges that included:
Inevitably, new challenges arose as the team worked its way through the list. They explored emerging technologies, collaborated with external partners, overcame frustrating setbacks, and tapped into their creativity.
Finally, after another year of blood, sweat and tears, the team had managed to create a professional and attractive-looking product that would fit the VRR brand perfectly; now able to stack seven high instead of just one, or five if you consider our previous concept. They were ready to launch the prototype of the Air7 at the World Cargo Symposium in March 2020.
Then COVID-19 arrived, and the world went into lockdown…
The launch of the prototype was cancelled, the supply chain was disrupted, and half of our personnel suddenly had to work from home. Our hopes of starting series production by Q2 2020 was put on hold.
Regardless, the project continued.
We announced online that the Air7—the world’s first inflatable AKE container—was ready for certification. Then the team got down to ironing out all the wrinkles of the blueprint to arrive at a fully validated product.
After many brainstorming sessions, we were eventually able to lower the overall weight and cost and, at the same time, overcome remaining hurdles such as:
The R&D team’s main concerns were the ability to produce a product that was strong enough to carry heavy loads, would stand up to the rigours of daily operational use, and would fit in an aircraft’s hold. In addition, production costs had to be viable.
It was a tall order, to say the least. But they succeeded despite all the obstacles put in their way. The Air7 is now ready for the testing and certification phase to ensure that it is completely airworthy.
In our next article we’ll explain the steps that we still have to take to produce our innovative product. We’ve come a long way, but we’re not over the finishing line yet. However, we’re pleased to say that the end is in sight.
If you’d like to know more about the Air7 or any of our other products, feel free to contact us or stay updated via our LinkedIn page.