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A Model for Aerospace Ambitions

Bell Helicopter needed to create buzz around their new 505 Jet Ranger X. Their ambitious plan was to build three full-scale mock-ups of the 505 Jet Ranger X for an international tradeshow in only six months. The challenge? No parts existed for these models. They needed to be built from renderings, design concepts, and incomplete CAD data. Multiple teams at Roush Industries made it happen.

What was the challenge?

Bell Helicopter envisioned the 505 Jet Ranger X as a lightweight, versatile aircraft designed for both commercial and private use. It features a spacious cabin that can accommodate up to five passengers. Equipped with a powerful and fuel-efficient engine, the 505 offers exceptional performance, advanced avionics, and a fully integrated glass cockpit for enhanced safety.

Bell wanted to promote its cutting-edge concept at an international tradeshow. But without any real parts, the 505 Jet Ranger X existed only in renderings, design concepts, and incomplete CAD data. Bell partnered with Roush to bring the project to life, enlisting multiple teams to design, build, and refine three full-scale models on a strict timeline ahead of the tradeshow.

What did we accomplish?

Bell partnered with Roush to bring the project to life, enlisting multiple teams to design, build, and refine three full-scale models on a strict timeline ahead of the tradeshow.

3
full-scale models
19,000+
attended the tradeshow

What services were provided?

Concept Design

In the aerospace development world, it is not uncommon to start exclusively with two-dimensional drawings, incomplete CAD data, and design concepts. Unlike traditional aircraft builds, the Roush design team could not rely on off-the-shelf parts, and initial design concepts often left room for interpretation.

Advanced digital tools and simulation software helped fill in the gaps. These tools allowed for virtual testing and iterative refinement before moving to physical fabrication. The process wasn’t without challenges — certain areas of the design were underdeveloped, and decisions had to be made with limited information. A collaborative approach with Bell’s engineers allowed our team to successfully lay the foundation for the next phase.

Advanced Composites

Advanced composites are critical to the 505’s design. These materials are stronger, lighter, and more resilient than traditional metals, offering enhanced performance and efficiency. The Roush advanced composites team, with their specialized knowledge of material science and manufacturing techniques, focused heavily on the model’s trim and seating components.

Our team designed lightweight yet highly durable seating structures that reduced overall weight while maintaining strength. Custom trim elements enhanced the aesthetic appeal of the cabin and contributed to a quieter, more comfortable ride for passengers.

Fabrication

Fabricating three complete models in Roush studios was the final step before unveiling the 505 Jet Ranger X. With no initial parts to work from, the team had to fabricate everything — from the main rotor blades to intricate auxiliary parts.

Our fabrication team of technicians, engineers, and machinists carefully followed the digital blueprints and used state-of-the-art machinery to bring the 505’s components to life. The team also relied on rigorous quality control measures to ensure that each model would function properly at the tradeshow.

What is the impact?

Building three tradeshow-ready helicopter models is a significant undertaking. But achieving this feat with only digital renderings is a unique challenge. This project proves there is no limit to aerospace development, especially when multiple teams at Roush collaborate with an ambitious leader in the industry.

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