Modular Maintenance Platforms

Challenge: Efficient Storage Solution in Limited Hangar Space
Solution: Modular Maintenance Platform by Spark Ops Metalworks
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Earlier this year, Spark Ops Metalworks was entrusted with a project to develop a specialized solution for a major aircraft manufacturer’s Maintenance, Repair, and Overhaul (MRO) facility in Macon, Georgia. With growing MRO operations across the southern U.S., including facilities in Tennessee and Texas, the client faced challenges with restricted space.
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One of the critical challenges was finding a secure and efficient storage method for aircraft seats after removal—a process that demands meticulous handling to maintain both safety and workspace efficiency. Storing seats on the hangar floor was not an option, as it created clutter and occupied essential work areas.

Spark Ops developed a modular maintenance platform using patented DSS components to address this need. The custom-built platform provides a designated space for securely storing seats off the floor, while offering room for tools, toolboxes, and other equipment. Open space beneath the platform further optimizes storage for specialty parts and additional toolboxes, maximizing floor availability for critical maintenance tasks.

A dedicated team from Spark Ops, including CEO Bryan and seven team members, traveled to Georgia to complete the project, assembling three custom structures on-site in just two days. The modular, height-adjustable platform’s design allows for rapid assembly, using only minimal tools. The platform’s modular design, made from in-house manufactured aluminum components, is akin to a LEGO build. It reduces the need for ladders, scaffolding, and scissor lifts, allowing the MRO facility to maintain a streamlined, clutter-free workspace. While some specialty lifts may still be required depending on the aircraft and facility needs, the platform minimizes the amount of excess equipment needed.

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