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Custom Development, Testing & Procurement

A practical workflow for custom aviation glass development, sampling, testing, documentation, change control, supply, and procurement.

BO-Glass inspection evidence

Project entry guide

Stage-gate development flow

Custom Development, Testing and Traceability

A successful sample proves that one part can be made; it does not yet prove that the design, process, and inspection route are repeatable. Custom development turns an application need into controlled geometry, optical targets, tooling, samples, acceptance evidence, and traceable production records. This chapter explains why each step exists and how it reduces uncertainty for both the OEM and the glass manufacturer.

Controlled project inputs and responsibility

Begin with one controlled project package identifying the application, equipment model, intended use, responsible design organization, approval route, confidentiality and intellectual-property constraints, annual demand, target schedule and required evidence. Separate customer requirements from supplier proposals and record every open assumption before quotation or tooling approval.

The customer or responsible design organization controls approved design data, interfaces, application requirements, complete-equipment qualification and acceptance of technical changes. The glass supplier controls only the material, manufacturing, inspection, documentation, packaging and notification duties assigned by the contract. A physical sample or technically comparable optic does not transfer design authority or establish approved interchangeability.

Drawings, models and legacy samples

A 3D model efficiently defines nominal geometry, while a controlled 2D drawing or model-based definition establishes contractual product manufacturing information: datums, tolerances, material, optical zones, coatings, edge limits, inspection methods, marking, packaging and revision. Identify the controlling dataset and resolve conflicts before release. A visually complete CAD model is not an acceptance plan.

For legacy reconstruction, document sample identity, equipment model, orientation, service history, wear, damage and cleaning limits before measurement. Use multiple specimens where possible to separate original intent from production spread and service wear. Measure functional datums, profile, thickness, optical angles, spectral behavior, texture, mounting and sealing interfaces; record unknown material, strengthening, coating and tolerance assumptions.

Reconstruct the new nominal definition from functional intent and complete-equipment evidence rather than averaging every worn feature. The responsible design organization must confirm data rights, assumptions, new drawing and approval route. A legacy sample supports discovery but cannot supply original certification status, drawing tolerances or interchangeability by itself.

Controlled input package

DFM, prototypes and production-representative approval

DFM reviews material availability, forming or machining route, radii and draft, thickness transitions, parting line, optical surfaces, loaded edges, seal lands, strengthening, coating, printing, cleaning, measurement access, yield, tool life and packaging. Rank tolerances by functional sensitivity and close technical risks before production tooling.

Define the sample quantity, drawing revision, material, process, inspection and decision owner before manufacture. Disclose hand finishing, selection, temporary material or any deviation. A signed golden sample is only a supplementary visual reference unless it is linked to the controlled design, build route, measurements and approved differences.

Where invoked by contract or the quality system, SAE AS9102C defines aerospace first-article inspection requirements. A normal dimensional report must not be described as an AS9102 FAI unless the required process and documentation actually apply.

First article, inspection and traceability

Product evidence should connect the released design to the production route and lot. Select key characteristics from optical, mechanical, sealing and configuration risk; define the method, sample plan, calibration status, acceptance limit, reaction rule and retained data before production.

Lot definitions should isolate material, cavity, coating or other common-cause variation without becoming unmanageable. Serial numbers are not automatically superior to lot traceability. Track cavity and process trends separately, retain approved reference parts where useful and test the recall path so affected shipments can actually be identified.

Define first-article triggers before production: a new part or drawing revision, lapse in production, material or source change, new or repaired tooling, cavity change, manufacturing-site or subcontractor change, major process revision, or an inspection method that is no longer demonstrably correlated. The customer may require a full or partial FAI depending on the affected characteristics. FAI confirms one production configuration against design data; ongoing conformity still depends on stable process controls, sampling, reaction limits and lot release.

BO-Glass inspection evidence

Changes, deviations and nonconformance

Planned changes and unplanned nonconformities require different controls, even when both ultimately need design-authority review.

1. Identify and segregate the affected material or product.
2. Define scope by lot, cavity, process and shipped-product traceability.
3. Preserve data and samples before rework or disposal.
4. Evaluate function and escapes, including any effect on delivered equipment.
5. Obtain authorized disposition for scrap, return, controlled rework or concession.
6. Reinspect after rework for every characteristic the operation could alter.
7. Determine root cause and corrective action proportionate to risk.
8. Verify effectiveness on later production and communicate required records.

The supplier must not independently approve use-as-is when the condition can affect optics, strength, sealing, approved design data or certified equipment configuration. Temporary deviations remain traceable by quantity, lot and expiry.

Procurement and BO-Glass Custom Manufacturing Support

Two quotations can describe very different supply scopes even when they show the same part number and quantity. Tooling ownership, inspection coverage, optical testing, documentation, packaging, change control, and long-term replacement support all affect the real cost and risk. The final chapter helps buyers make those differences visible and shows how BO-Glass reviews a requirement before proposing a practical production route.

Second source, tooling and low-volume supply

For FAA-certified airport lighting, review AC 150/5345-53D, its May 2026 Addendum and FAA's linked non-OEM component letters. In the covered AIP/PFC and other stated situations, maintaining the certified equipment configuration can expressly restrict non-OEM replacement components.

Low-volume supply still needs controlled acceptance. Select CNC processing, prototype or production molds, manual pressing or hybrid finishing according to geometry and real demand. Define tool ownership, cavity strategy, adjustment rounds, storage, maintenance, expected life, minimum economic batch and final production route. Qualification should use the alternate source's own production-representative samples; another supplier's process approval does not transfer.

Second-source qualification

Packaging, long-term agreement and continuity

Packaging is a controlled production process. Protect optical surfaces, critical edges, coatings, orientation and traceability against contact, vibration, drops, compression, humidity, temperature, customs inspection and partial-pack handling. Validate the actual pack quantity and transport route, then inspect the optics rather than only the box.

A long-term agreement should define forecasts, pricing and lead-time assumptions, tool ownership and maintenance, material obsolescence, approved design status, record retention, change-notice time, temporary deviations, last-time buy, packaging, business continuity and delivery/quality metrics.

Do not use these terms interchangeably. Record the owner, storage condition, shelf or review period and disposition rule for every inventory commitment. Review delivery, escapes, yield, engineering changes and corrective actions periodically so continuity planning remains tied to the approved configuration.

International packaging concept

BO-Glass manufacturing and project evidence

BO-Glass can support build-to-print, developing-design and sample-reconstruction projects through an agreed division of responsibility.

Public BO-Glass case studies demonstrate representative capabilities and project types. They do not certify another part, transfer confidential design evidence or prove approval of a customer's complete equipment. Project-specific drawings, raw inspection data, FAI packages and acceptance records are supplied only as agreed through the controlled commercial and quality process.

Supplier qualification should connect capability to the proposed part rather than rely on facility photographs alone. Review the intended material family, forming or machining route, relevant surface processes, inspection range, calibration control, nonconformance system, subcontractor controls, capacity and similar production experience. A capable laboratory instrument does not prove that every characteristic will be measured; the quotation and quality plan must identify the actual method, aperture, fixture, sample size, result format and acceptance limit.

For lot release, request only evidence that supports a decision: part and revision, material and production lot, tool/cavity where relevant, process batch, inspection method and equipment, calibration status, sample size, measured result, limit, disposition, reviewer and date. Add raw spectral, profile or image data where agreed. Excess generic paperwork can hide the absence of one critical functional record, while a concise traceable package can support efficient review and later investigation.

Production and inspection evidence for supplier qualification

A credible supplier review connects people, equipment, methods and records. Facility images can confirm that relevant workflows are present; customer acceptance still depends on records tied to the correct drawing revision, sample or production lot.