Simulation-informed design is the key to building environments that support Ornge paramedics in the air so they can better serve their patients, and this is especially true in the PC-24.

From a distance, the large wooden “bones” resemble something that might be found in a museum of natural history. Nicknamed “the whale skeleton,” this enormous contraption is not about the past but about the future: designing the next generation of Ontario’s air ambulances.
 
An important step has been taken in the process of introducing a new, specialized aircraft into the provincial air ambulance system. Ornge has teamed up with the talented students at Confederation College, the design engineers of Australian systems integrator HeliMods, and longtime Swiss aerospace manufacturer Pilatus to build and test the interior of a Pilatus PC-24 jet: the newest up-and-coming addition to the province’s advanced air ambulance fleet.
 
By the end of 2029, Ornge’s fleet will expand to include an additional four Pilatus PC-12 fixed wing planes and two PC-24 jets. This is the first time in Ornge's history that jet planes will be utilized to transport sick and critically injured patients across Ontario. However, this feat would not be possible without the collaborative effort of multiple organizations spanning three different continents, connected through a shared digital design process allowing for valuable input and feedback from our frontline crews. With a new aircraft being introduced, a new medical interior must also be designed and integrated to ensure paramedics can safely and effectively deliver life-saving care to Ontario patients.
 
The project began back in November 2024 when HeliMods, the aerospace technology company responsible for designing and integrating critical medical systems to meet Ornge’s fleet specifications, was looking for opportunities for local makers to help to develop and build the shell or “whale skeleton” of the PC-24 interior.
 
“Looking for new and innovative ways to make representations, to build mock-ups, and to help facilitate the design development process in a meaningful way is really what we’ve been trying to do here,” says Will Shrapnel, owner of HeliMods. “Being able to develop full-scale, 1:1 mock-ups on location lets paramedics, air crews and all those involved in operations to get more hands and understand their environment better. This also lets us work as a team to validate clinical workflows early and determine together the best way to configure the aircraft for critical air ambulance missions.”
 
Ornge’s project manager Sharon Edwards then connected with Chief Engineer Sean Fillion to determine how the “whale skeleton” could be brought to life. Fillion thought this would be an excellent opportunity to engage local talent that might also be interested in future careers in aviation.
 
After connecting HeliMods’ program manager Dion Schulz with Chris Grenke, Manufacturing Technical Coordinator at Confederation College, the College’s manufacturing faculty and students connected online with HeliMods design engineers in Australia, and through the sharing of PC-24 digital design files were able to translate HeliMods’ 3D vision into precision-cut plywood components in country, ready to assemble.
 
“We have a lot of collaborative projects that we do, specifically for local communities,” explains Grenke. “We want to promote Thunder Bay as a whole and better equip students with the tools that they need to produce parts for the end users. From a global aspect and with a design this big, this is one of the bigger projects we’ve worked on.”
 
“This project highlights the strength of industry collaboration and the value of applied, hands-on learning,” said Michelle Salo, President of Confederation College. “Our faculty, staff and students were proud to contribute their skills to an initiative that supports critical patient care across Ontario while also providing meaningful, real-world experience.”
 
Once the pieces were produced and packed by Confederation College students, the “whale skeleton” was shipped to Ornge’s Oakville storage facility where Ornge aircraft maintenance engineers, HeliMods engineers and Pilatus representatives built the interior prototype.
 
“This was a global team effort to bring all this together and create the machines that are life saving and critical for Ornge. Our ultimate goal is to create these special missions aircraft to meet the mandate of Ornge. From the ground-up, working with these talented individuals and amazing machines – this was pretty special to see come to fruition,” says Layton Harrington, Program Manager for Pilatus Business Aircrafts.
 
Once the “whale skeleton” was built, the next step of the process began, simulation-informed design. On September 24, paramedics and paramedic leads from Ornge’s bases ran simulations to determine important design elements, such as the best configuration of seats, stretchers, equipment and storage. Each time a change or a suggestion was made, the Ornge team would consult with Pilatus and HeliMods representatives, and the fuselage would be altered real-time for additional consideration, testing and validation.
 
This process of testing, redesigning, retesting, and reviewing took place over two full days.
“What surprised me most about this project is the level of collaboration with the organizations involved,” says Ornge Critical Care Flight Paramedic Ryan Daubney. “I didn't realize how much input Pilatus as well as HeliMods would have. What started as an idea grew into this functional mock-up that we are able to work in today. It was very eye opening to see other people’s perspectives on this project and the final result.” Having grown up and still residing in Northern Ontario, Daubney emphasizes what a significant impact this aircraft will have for Northern communities and patients.
 
Simulation-informed design is the key to building environments that support Ornge paramedics in the air so they can better serve their patients, and this is especially true in the PC-24. The PC-24 will be used for specialty missions and transports including dual patient transports, preemie infant transports, and other long-haul missions. This asset will be the largest designated specialized asset in Ornge’s fleet.
 
“Our mock-up is designed to help us create an environment where we can simulate a patient care setting that is comparable to what we will use in real life,” explains Justin Pyke, Director of Operations, Programs, and Performance at Ornge. “This is an excellent opportunity to get hands on with the aircraft, structure, and equipment, to make changes as we work through different simulations, and to understand how best to create an environment that will work for paramedics and patients.”
 
The data, decisions and comments from the “whale skeleton” build and simulations will now be utilized in the next steps of the PC-24 design all in preparation for delivery in 2028. The PC-24 prototype will be used for further education, simulations, and training to give an accurate representation of saving lives in limited space.
 
The “whale skeleton” is a true labour of cooperation which would not be possible without the hard work of all involved. Shrapnel concludes that for everyone, the whale project has been much more than the sum of its parts. “There’s so much value in seeing the end results of these efforts, which is the great work that Ornge will be able to do across the province. For everyone that has been involved in this global collaboration, when they see an Ornge aircraft flying overhead, they can genuinely say ‘Hey, I had a part of that.’”

 

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