Efficient, reliable, and cost-effective
FAA Certified and validated by multiple national civil aviation authorities; this system meets fuel tank safety rules without complexity or costly modifications.
Watch how AerSafe reduces the risk of fuel tank explosions
AerSafe is a certified ignition mitigation system that helps operators meet FQIS and FTFR requirements—without the cost, complexity, or lead times of nitrogen inerting systems.
PROTECTION
Compliant, cost-effective, reliable, and quick to install
Functionality
AerSafe is a fuel tank ignition mitigation system approved by the FAA, EASA, Transport Canada, ANAC, Mexico DGAC, and Argentina DNA as a method of compliance with 14 CFR 25.981(c) and 121.1117. It is one of the few FAA-approved solutions that satisfies both the Fuel Quantity Indication System (FQIS) airworthiness directives and the Fuel Tank Flammability Reduction (FTFR) rule.
The AerSafe system limits the amount of available oxygen that can ignite fuel vapors and prevents sparks from initiating an explosion. It has been tested and developed to exact tolerances to fill the cavity of Boeing and Airbus center fuel tanks.
The AerSafe system is comprised of multiple blocks of highly porous material which completely fill the aircraft center tank interior, with negligible voids. The system properties allow for free movement of fuel within the tank and into the fuel delivery system to the engines, while preventing gross over-pressure or an explosion within the tank by limiting the extent of any vapor/air ignition to a small local detonation, preventing it from propagating through the tank.
Benefits of AerSafe
AerSafe enables operators to meet FQIS and FTFR requirements at a significantly lower cost than OEM inerting systems, while offering a range of practical advantages. It can cost up to 50% less than OEM alternatives and is delivered as a complete prefabricated kit, making installation efficient and straightforward. The system can be installed at hangars worldwide with minimal downtime, and it requires no post-installation flight testing or specialized tooling. Unlike traditional systems, AerSafe does not use an air separator module (ASM), which eliminates the risk of ozone-related failures. It also contains no moving parts or components that require ongoing maintenance or replacement. Additionally, both modification and de-modification can be completed without structural changes, offering operators maximum flexibility and ease of use.
Applicability
AerSafe is designed for passenger aircraft operating under 14 CFR Parts 121, 125, and 129 that must comply with the FQIS and FTFR mandates (see: FAA Advisory Circular 120-98A).
Airbus Aircraft
| Model | FAA Supplemental Type Certificate (STC) |
| A319 | ST04010NY |
| A320 | ST04010NY |
| A321 | ST04010NY |
| A330 | Pending |
Boeing Aircraft
| Model | FAA Supplemental Type Certificate (STC) |
| 727 Series | ST04515AT |
| 737 Classic Series | ST03589NY |
| 737 NG Series | ST02980NY |
| 757 Series | ST04534AT |
| 767 Series | ST03599NY |
| 777 Series | ST04203NY |
Additional Certifications
Please ask an Engineered Solutions specialist for information on international approvals or additional certifications.
100+
AerSafe kits ordered for commercial and cargo fleets
35
Global customers served, including airlines, lessors and MROs
7
FAA STCs held for AerSafe—with an 8th in progress for the A330
7
Aircraft families supported, including Boeing and Airbus models
Current FAA Airworthiness Directives
AerSafe offers a certified method of compliance for several FAA airworthiness directives (ADs) related to FQIS systems.
Applies to: Boeing 757-200, -200PF, -200CB, and -300 series airplanes
AerSale AMOC: Ref: 784-22-2366
STC: ST04534AT
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM).
Applies to: Boeing 727, 727-100, 727C, 727-100C, 727-200, and 727-200F series airplanes, equipped with Boeing body-mounted auxiliary fuel tanks.
AerSale AMOC: Ref: 7A0-21-8580
STC: ST04515AT
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM).
Applies to: Airbus SAS airplanes for which AerSafe was granted an Alternative Means of Compliance (AMOC)
- Model A318-111, -112, -121, and -122: Not covered by AerSafe
- Model A319-111, -112, -113, -114, -115, -131, -132, and -133: AMOC
- Model A320-211, -212, -214, -231, -232, and -233: AMOC
- Model A321-111, -112, -131, -211, -231, -212, -213, and -232: AMOC
- Model A330-201, -202, -203, -223, -223F, -243, and -243F: Currently in development for new STC, expected certification by the end of 2025
- Model A340-211, -212, -213, -311, -312, -313, -541, and -642: Not covered by AerSafe
STC: ST04010NY
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM).
Applies to: Boeing 777-200, 777-200LR, and 777-300 series airplanes
STC: ST04203NY
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM).
Applies to: Boeing 737-600, -700, -700C, and -800 series airplanes
STC: ST02980NY
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM)
Applies to: Boeing 767-200, -300, -300F, and -400ER series airplanes
STC: ST03599NY
Note: AerSafe does not cover the -400 model
Status: When AerSafe is installed, this AD is not applicable to aircraft equipped with the Ignition Mitigation Means (IMM).
FQIS and FTFR Background
The FAA’s published airworthiness directives (AD) focused on the fuel quantity indication system for several different airframe platforms. The ADs were issued to prevent ignition sources inside the center fuel tank, which in combination with flammable fuel vapors, could result in a fuel tank explosion. AerSafe was originally developed to meet the FAA’s FTFR mandate and is now certified as an Ignition Mitigation Means (IMM) under 14 CFR 25.981 (a)(c)(d).
The FAA’s FTFR rule requires operators of certain transport category aircraft to mitigate the possibility of fuel tank vapor ignition. To avoid being grounded, all affected passenger aircraft operating under FAR Part 121 within or into the United States must be equipped with an FAA-approved ignition mitigation means. Affected aircraft models include the Airbus A319, A320, A321, and A330 and the Boeing 737, 757, 767, and 777.
AerSafe Development
According to FAA Advisory Circular 120-98A, OEMs offer nitrogen inerting systems to meet FTFR requirements; however, these systems are expensive, have lead times of 6-12 months, and are costly to maintain. AerSale developed AerSafe as a safe, reliable, and cost-effective alternative. While initially introduced for FTFR compliance, AerSafe now supports operators in meeting the requirements of the FQIS airworthiness directives.
Frequently Asked Questions
Find answers to common questions about AerSafe’s certification, installation, performance, and maintenance.
The FAA has issued several airworthiness directives (ADs) targeting specific Boeing and Airbus airframes. The purpose of the AD is to prevent ignition sources inside the center fuel tank, which, in combination with flammable fuel vapors, could result in a fuel tank explosion and consequent loss of the airplane. Currently, there have been no approved Alternate Means of Compliance (AMOCs) for commercial passenger aircraft. The installation of AerSale’s AerSafe Ignition Mitigation Means (IMM) renders the FQIS AD not applicable.
AerSafe is an FAA-certified Ignition Mitigation Means (IMM) under 14 CFR 25.981(a)(c)(d) that uses a reticulated polyurethane foam to fill the center fuel tank. The AerSafe system limits the amount of available oxygen that can ignite fuel vapors and prevents sparks from initiating an explosion. It has been tested and developed to exact tolerances to fill the cavity of Boeing and Airbus center fuel tanks.
The AerSafe system is comprised of multiple blocks of highly porous material which completely fill the aircraft center tank interior, with negligible voids. Multiple individual foam blocks are installed through the existing inspection/maintenance access panels, in accordance with installation drawings and the engineering order. The system properties allow for free movement of fuel within the tank and into the fuel delivery system to the engines, whilst preventing gross over-pressure or an explosion within the tank by limiting the extent of any vapor/air ignition to a small local detonation, preventing it from propagating throughout the tank.
AerSale utilizes a precision Hot Wire cutting machine that cuts the foam to precise tolerances at our manufacturing facility; it also singes the ends of the foam leaving no rough edges that can chafe off to create FOD or clog the filters. After the cutting of our foam, we then thoroughly vacuum the blocks to ensure no particulate has been trapped within the pores, further preventing the possibility of FOD. This work is completed before the kit is ever shipped, with parts individually packaged in AIR 4170 black 4mil plastic bags as required by our STC data package and marked by individual part number to ensure a smooth installation.
For Boeing products, excluding the B757, under paragraph (c) applicability, the AD “excludes” airplanes equipped with an FRM (flammability reduction means) approved under 25.981(b) (NGS Systems) or airplanes equipped with ignition mitigation means (IMM) , i.e., AerSafe, which is approved under 25.981(c). As an FAA-approved IMM solution, the installation of AerSafe renders the AD not applicable to any aircraft that incorporates the AerSafe solution.
The AD for Airbus products and the Boeing 757 was written in such a way that it neglected to mention under paragraph (c), aircraft fitted with an IMM solution. As such, AerSafe is a certified Alternate Means of Compliance (AMOC).
AerSafe Certifications
Boeing
B727-200 – ST04515AT
B737CL – ST03589NY
B737NG – ST02980NY
B757 – ST04534AT
B767 – ST03599NY
B777 – ST04203NY
Airbus
A320 FAMILY – ST04010NY
A330-200 - Expected Q4 2025
AerSafe is available for immediate installation. Lead time is approximately four (4) weeks for narrowbodies and six (6) weeks for widebody aircraft. Aircraft downtime for installation is approximately two (2) days.
The installation kit includes all required materials, placarding, and technical data.
AerSafe can be installed at any location around the world that has the capability to conduct fueling and defueling. Additionally, fuel sampling and testing should be available. The aircraft must be hangared during AerSafe's installation, with an empty center fuel tank.
Installation at AerSale's Roswell, New Mexico location is included in the AerSafe price. If installation is performed at any other location, the purchaser will be responsible for the cost of shipping and handling of the kit, travel costs for two (2) AerSale technicians, and any other unexpected expenses involved with the installation.
After installation, AerSafe requires no maintenance. However, after ten (10) years, a visual inspection is required to determine the condition and safety of the system.
AerSafe may be procured from AerSale for third-party installation. A Right-to-Use must be purchased prior to any STC data or materials being furnished. It is important to note that installation warranties are not provided if AerSafe is not installed by qualified AerSale technicians.
The AerSafe system is considered a fully packed system and no means of adhesion is required. The system is engineered to fit into the confines of the center fuel tank with voids as required for components and system design.
AerSafe is part-number specific and may be purchased individually.
Once the kit is installed, it cannot be removed and installed on another aircraft. The installation kit and data package are aircraft-specific.
In the event that the center fuel tank needs to be accessed for maintenance, the AerSafe system can be removed and reinstalled. The fuel tank must be de-fueled and properly ventilated.
AerSafe has a life expectancy of 10 years.
The warranty is valid for ten (10) years, provided that AerSafe was installed by qualified AerSale technicians.
If AerSafe was installed by qualified AerSale technicians, AerSale will continue to provide support to the customer after installation.
Meet mandates—without pricey OEM system costs
AerSafe delivers certified compliance with lower costs and minimal installation time.