When a fatigue model is extrapolated,
the failure is total.
Aerospace decisions run on data that is always expensive and incomplete: flight test programs with limited envelope coverage, material properties from coupon tests that may not represent the article, and maintenance intervals based on statistical models that assume representative usage. Every system you trust today extends those models with safety factors. ARACHNE labels the extensions as ignorance and escalates.
Four gaps no current
tool admits openly.
These are not edge cases. They are the daily reality of aerospace operations. And every existing system handles them the same way: it guesses, assigns a confidence score, and moves on.
Flight Test Coverage Gaps for Certification
Flight test programs cannot cover every combination of altitude, speed, weight, and temperature. The uncovered envelope is extrapolated by analysis. The assumptions in that extrapolation are rarely explicit.
Fatigue Life Prediction on Limited Test Data
Fatigue life is predicted from coupon tests and component tests. The full-scale article may differ in material, processing, or stress concentration. The prediction uncertainty is rarely propagated to the operational limit.
Maintenance Interval Extension Justification
Maintenance intervals are initially conservative. Operational data supports extensions. The statistical basis for extension depends on fleet size, usage monitoring accuracy, and failure mode coverage. Small fleets have weak statistical power.
Supply Chain Part Qualification at Scale
Aerospace parts are qualified by design and process. Supplier changes, process deviations, and material lot variations may invalidate the qualification. The traceability from part to qualification basis is often incomplete.
Every claim carries proof.
Every gap carries a label.
The Margin Expansion organ binds 36 required input nodes before any bounded action. In pharma, those nodes include stability status, CoA completeness, safety signal provenance, and regulatory precedent. Missing any one is not a failure—it's labeled ignorance, escalated, and recorded.
Stability-Gated Batch Release
Hard gate: no batch releases without completed stability profile or explicit operator override with versioned reasoning.
PROVEN · RECOMPUTABLESignal Provenance Tracking
Every safety signal traced to source database, query date, and confidence threshold. Stale signals flagged automatically.
TESTED · VALIDATING LIVECoA Completeness Verification
Incoming certificates checked against 14 required fields. Incomplete CoAs halt the gate—never silently accepted.
ARCHITECTURE · DOCUMENTEDRegulatory Delta Audit
Every submission tracked against its evidentiary base. When evidence evolves, the delta is computed and surfaced.
IN DEVELOPMENTWhere proof replaces
confidence scores.
These are not aspirational. Each use case below maps to a live, checkable proof in the validation ledger. You can recompute every claim yourself.
Supplemental Type Certificate Modification LIVE PROOF
An MRO proposes an STC for a cabin modification affecting emergency egress. ARACHNE evaluates the certification basis against 36 nodes: original type certificate data, modification structural analysis, egress simulation results, and flammability test coverage.
- Egress simulation based on average passenger, not 95th percentile → flagged
- Flammability test on material sample, not modified configuration → ignorance
- Structural analysis uses simplified load path, not full FEM → labeled
- STC approval conditional on test gap closure or operational limitation
Engine Life-Limited Part Retirement ARCHITECTURE PROVEN
A turbine engine operator evaluates whether to retire a life-limited part at its certified cycles limit or seek an extension. ARACHNE evaluates the extension request against 36 nodes: usage monitoring accuracy, environmental exposure history, inspection findings, and fleet-wide failure data.
- Missing certificates halt qualification—not waived, not assumed
- Environmental exposure estimated, not measured → labeled ignorance
- Fleet failure data: 0 failures in 50,000 cycles → statistically weak
- Extension granted with reduced interval and enhanced inspection only
Composite Repair Structural Adequacy VALIDATION LEDGER
A composite skin panel is damaged and repaired using a bonded patch. ARACHNE evaluates the repair against 36 nodes: damage assessment completeness, repair procedure qualification, adhesive cure monitoring, and post-repair inspection coverage.
- Damage assessment by visual inspection only → NDI not performed → ignorance
- Repair procedure qualified on flat panel, not curved skin → applicability gap
- Adhesive cure monitored by time-temperature, not degree-of-cure → flagged
- Repair released with flight restriction and re-inspection interval
Not projected.
Proven.
Every number below is recomputable from public sources. No vendor claims. No confidential data. Just proofs you can run yourself.
"We had a fatigue model that passed every certification review. It was not until ARACHNE asked us to label which data points were measured and which were extrapolated that we realized 40% of our life prediction was assumption, not evidence. That changed how we certify."