Robertson Fuel Systems, A Heico Company

Nowhere is safety more crucial than in military aviation, where pilots operate in high-stakes environments that leave no room for error. A never-ending pursuit of safety, therefore, is paramount to them. Keeping this philosophy at its core, Robertson Fuel Systems — a HEICO company — has developed numerous innovative crashworthy survivable fuel systems for the military, efforts which have also yielded safer products for commercial aviation.

Robertson Fuel Systems was started by Dr. S. Harry Robertson, a man who dedicated his life to researching, developing, and manufacturing safer fuel systems for military and commercial aviation. His work included conducting rigorous crash tests and drop tower experiments to understand human survivability in aircraft crashes. The crashworthy fuel system is the outcome of that research, which forms the backbone of the company’s current offerings. Its fuel tanks also incorporate self-sealing capabilities designed to withstand extreme ballistic threats, optimizing the safety and survivability of the aircraft and its crew.

Even more impressive, Robertson can develop and have fuel systems flying within just 12 months, where similar programs typically take three to five years. What sets Robertson apart is its ability to rapidly develop and deploy products which meet stringent government and military survivability standards.

“We provide mission commanders more than just reliable fuel solutions—we deliver fuel tanks that enhance both safety and operational success,” says Shane Openshaw, Vice President, Programs. “Our tanks are designed to ensure that even in the event of a crash, fuel remains safely contained to prevent post-incident fires.”

Robertson’s fuel system solutions offer ballistic self-sealing capability ranging from 7.62mm to 23mm threats, offering a lifeline in high-risk situations. In earlier designs, a highly flammable fuel system posed a risk in the case of survivable crashes or enemy fire, but Robertson’s fuel tanks have reduced those dangers, contributing to the preservation of lives. This commitment to survivability and mission success has established the company as a trusted partner in the most demanding environments, providing clients with the safest and most dependable fuel systems.

Next-level Fuel Systems

Robertson offers primary and auxiliary aviation fuel systems, ground vehicle fuel systems, crashworthy fuel cells and aviation support equipment with over 60 unique system variations. These solutions are on multiple military platforms worldwide, including the AH-64 Apache, H-60 Black Hawk, H-47 Chinook, V-22 Osprey, and UH-1Y Venom. In many cases, more than one product is available for each platform, including both internal and external auxiliary fuel tank options.

The aim is to provide mission commanders with maximum flexibility. For example, the Apache helicopter can carry one or two crashworthy, externally mounted auxiliary fuel tanks, each holding 125 gallons of fuel, the Combo-Pak, carrying 100 gallons of usable fuel along with some firepower, or both.

The Combo-Pak is one of Robertson’s most notable innovations, with an interesting backstory. Thanks to advancements in weapon accuracy, Apaches in combat were not consuming a full 1200 round magazine of 30mm ammunition during a typical mission, and often would return to base with ammunition remaining. It was clear additional fuel on board would enable the Apaches to stay in the fight longer and further extend the battle to the enemy. Recognizing this opportunity, the company designed, developed and built a 300-round magazine integrated with a 100-gallon fuel tank which can replace the original magazine. The balance between ammunition and additional fuel was a perfect “combination,” hence the name, “Combo-Pak.” The Combo-Pak can be swapped with the full-sized ammo magazine in less than 20 minutes, enabling rapid reconfiguration. The idea was implausible at first, but the company executed ingeniously and the Combo-Pak is now a standard addition to the Apache. This technology is a proven game changer in U.S. military operations, especially in Iraq and Afghanistan. The Combo-Pak has demonstrated its endurance during critical times by extending the Apache’s range by up to an hour, a distinct operational advantage in the field that the U.S. Army values highly.

From Concept to Combat

Robertson’s low non-recurring engineering (NRE) costs allow clients to be involved in developing and launching these kinds of new products. Whereas NRE costs are usually high in the defense sector, the company invests its own development funds. Products are delivered quickly to meet clients’ needs with fast approval and operational deployment. As a non-traditional defense contractor, Robertson can deliver products with more speed and at less cost, schedule, and development risk to the customer.

This distinct approach has proven effective in enabling the company to respond rapidly to urgent operational needs from both U.S. and foreign military forces. In one example, the UK Ministry of Defence had an urgent operational requirement for a reduced size crashworthy external fuel system for their WAH-64. The system was developed and flying in less than 6 months. The US Army Bradley Fuel Cell Survivability (BFCS) Kit was also a rapid response to an urgent U.S. Army need. Robertson designed and fully qualified the system in less than 18 months, and delivered over 4,000 BFCS kits.

Beyond designing and manufacturing innovative fuel systems, Robertson conducts qualification testing. The U.S. military requires extensive testing for fuel systems, including slosh and vibration, drop, and gunfire resistance. Whereas other manufacturers, including large aircraft OEMs, often rely on independent laboratories for these tests, Robertson has everything in-house, saving time and reducing costs.

The company offers training programs for maintainers, instructing them how to properly maintain their tanks. Military units and intermediate-level maintenance teams receive all necessary technical publications to maintain their tanks. For more complex issues, Robertson handles repairs and overhauls, either onsite or at its facility. This model empowers maintainers to perform maintenance at the lowest level and keeps systems in the field operational.

Robertson has continually evolved its manufacturing capabilities and material technologies, and more efficiently than ever before making fuel solutions. The company stays at the forefront of innovation, delivering uncompromised safety performance in crashworthy fuel systems that bring our Servicemen and Servicewomen home safely.

As Openshaw puts it, “Not a single service member has perished in a post-crash fire when our product is on the aircraft. They survive the crash, our fuel tank holds up, and they make it home to their families.”