Safety-Driven Craftmanship Explained

Safety-driven craftsmanship is a foundational tenet for our team at Sesame Technologies, Inc. As a US-based, global leader in high-temperature aviation ground support solutions, it is our commitment to design and manufacture the world’s finest equipment available to the aviation and aerospace industry.

Safety-driven craftsmanship means that every stitch, every weld, and every process completed in our facility is done with the real-world safety of the final user in mind. We know that our customers put not only the protection of their aircraft, but the safety of their personnel and passengers in our hands. Our products are tasked with protecting vital systems that ensure safe transportation for everyone, from commercial passengers on holiday to mission-critical military operations.

From material procurement to quality control procedures, every step of our manufacturing process is designed to maximize the quality of our craftsmanship with the safety of the end user in mind.

Material Procurement

Safety-driven craftsmanship informs our work long before production starts. It begins with material selection. By sourcing only the highest-quality materials available, we build our aviation ground support products to stand the test of time, withstand the elements, and continually push our industry forward.

High-Temperature Materials

One of our primary focuses when it comes to material selection is choosing materials that can stand up to the heat. We specialize in high-temperature ground support equipment because many aircraft sensors and probes, such as pitot probes, are heated.

If heat is accidentally triggered, pitot probe covers that are not high temperature will melt onto and contaminate the probe, which will make flight dangerous due to unreliable airspeed indications.

That’s why our covers are made from high-temperature materials, including Arlin™ Nomex®, Kevlar®, and Kevlar® EXO™. These materials withstand higher temperatures than polyester and vinyl and instead of melting onto heated probes they dissipate preventing contamination.

In addition to their high-temperature tolerance, these materials also provide abrasion resistance and durability, meaning products constructed from them last longer.

Other Premium Materials

In addition to high-temperature materials, we also source premium hardware, 316 L stainless steel, carbon fiber, aircraft-grade aluminum, and other solid-phase polyamides.

Every material we use in our products is carefully evaluated for quality, consistency, and suitability before it enters our manufacturing process. By investing in premium materials, we help ensure that our products continue performing when operators need them most.

Precision Fitment

When it comes to preventing damage and FOD ingress, precision fit is vital. A poorly fitting cover could easily accidentally be removed from the aircraft or could fail to prevent contamination from the elements due to gaps between the cover and the aircraft. That’s why precision fitment is a core part of our manufacturing process. Our quality control team verifies that each cover matches the specifications developed by our research and development team to ensure accurate fit.

SPIDER Precision Fit System

When it comes to aircraft engine protection, precision fit becomes even more specialized than other products. Each engine model has unique dimensions. Some engines are not completely round. And some aircraft of the same make and model have different engines due to manufacturer options or re-engining programs.

To meet the complex requirements of engine protection fitment, we designed and built a custom device named the SPIDER Precision Fit System. This device features adjustable components allowing it to mimic the specific curvature and dimensions of each engine model. During quality control checks, each engine shield manufactured is placed inside the device to ensure it fits the intended aircraft perfectly.

When aircraft operators receive one of our products, they can trust that it was designed, manufactured, and inspected with the intended aircraft in mind.

Foreign Object Debris Awareness

Foreign object debris (FOD) remains one of the aviation industry’s most persistent hazards. Even small contaminants can cause significant damage to aircraft systems, engines, and probes.

Foreign object debris awareness is vital to ensure covers are not contaminated during manufacturing. This practice requires specialized equipment and work environments. Our focus is to ensure our products remain free of FOD or contamination of any kind. Preventing FOD contamination requires discipline throughout the manufacturing and packaging process.

ISO Class 8 Cleanroom

All our Arlin™ Kevlar® and Kevlar® EXO™ products are manufactured in a custom-built ISO class 8 cleanroom with the most sophisticated production equipment available. This controlled workspace helps reduce airborne particles, fibers, dust, and other contaminants that could compromise product integrity.

FOD-Proof Packaging

Our commitment to FOD prevention extends beyond the walls of our facility. Our products are shipped in FOD-proof packaging to protect them from contamination during transportation and arrival at their destination. Our FOD-conscious packaging process helps ensure that products arrive ready for immediate use without introducing unnecessary risk to aircraft operations.

By treating FOD prevention as a continuous responsibility rather than a final inspection step, we help support safe aviation operations for our customers worldwide.

Quality Control Processes

Rather than relying solely on final inspections, we incorporate quality checks throughout our manufacturing process. This approach allows us to identify issues early, maintain consistency, and ensure that every product meets our standards before it reaches the customer.

Our quality control process includes:

• Material quality validation and inspection
• In-process manufacturing quality inspection
• Dimensional and fitment validation
• Packaging verification
• Final quality review prior to shipment

Driven By Quality

As a manufacturer of protective aircraft equipment, we understand that our products play a role in protecting the safety and well-being of aircraft pilots, crew members, and passengers every day. Safety-driven craftsmanship is our commitment to honoring that responsibility through superior materials, precision fitment, FOD prevention, and rigorous quality control.

We are confident in the superior craftsmanship and materials used to manufacture our aircraft products. Our commitment to customer satisfaction, combined with state-of-the art manufacturing techniques and materials, makes Sesame Technologies, Inc. a trusted partner for aircraft manufacturers and owners worldwide.

At Sesame, we design, develop, and manufacture aircraft protection solutions for military, commercial, and executive aviation operations. Whether your operations are experiencing pitot probe contamination due to low-quality covers or other failures due to poor craftsmanship, our team has safety-driven solutions that can improve your operations. To start implementing aircraft protection and personnel safety strategies for your organization, reach out to our team of aircraft protection experts.

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