Engineering Report - Public Summary (Redacted)

Starlink Mini - Category 5 hurricane-force wind loading

Prepared for: Air Vision Systems
Date: 05 February 2026
Version: Public summary v1.0 (redacted)

Air Vision Systems | Public Summary (Redacted) AVS logo

This document is a redacted public summary intended for website publication. Detailed CFD/FEA model inputs, boundary conditions, meshing strategy, solver settings, and appendices are intentionally withheld to protect Air Vision Systems intellectual property. A full technical report may be provided to verified partners under NDA.

1. Purpose and scope

This public summary describes a CFD-informed wind loading assessment and a structural durability review for an Air Vision Systems Starlink Mini mounting assembly under extreme wind conditions. The intent is to provide a transparent, high-level overview of engineering diligence without disclosing proprietary modelling details.

2. Wind loading basis (public)

Wind loading was assessed at the Category 5 hurricane-force threshold (around 252 km/h) per the NHC Saffir-Simpson scale. A CFD study was used to estimate wind pressure on the exposed surface; that pressure load was then applied to a structural analysis (FEA) to evaluate response. Detailed CFD/FEA inputs and solver settings are withheld in this public summary.

3. Test cases (foundations)

The mounting assembly was reviewed across multiple representative foundation/base conditions:

Plywood (wood) base
Structural steel base
Concrete base

4. Key outcomes (high-level)

Reported deformation was dominated by the polycarbonate lid; the maximum lid deflection reported was around 1.9 mm in the plywood case, with similar trends across other base conditions.
The aluminium 5052 base component carried the majority of stress; reported deformation at the tips of the aluminium component remained under 1 mm.
Reported fatigue safety factor in the presented plots exceeded 10 for the plywood and steel cases; the concrete case was reported as comparable to the steel case (public summary does not disclose full contour ranges).
Critical stress concentration was reported in base holding regions acting as spring-like features, rather than at the bolt locations.
A conservative modelling assumption treated the Starlink unit as rigid to highlight stress flow through the mount assembly.

5. Selected figures (redacted)

The figures below are included to illustrate typical outputs from the analysis. Geometry-revealing views and detailed settings are intentionally excluded.

Fatigue loading representation for the AVS Starlink Mini analysis: constant amplitude fully reversed load with Soderberg mean stress correction — Figure A: Fatigue loading representation (illustrative). Figure 7 Fatigue Loading used.

Figure B image withheld - geometry redacted in this public summary.

Figure B: Lid deformation contour (cropped; geometry redacted).

Exploded assembly overview of the AVS Starlink Mini mount showing the aluminium mount plate above steel, concrete and plywood base options — Figure C: Assembly overview (illustrative only; annotations removed).

Total deformation FEA results for the plywood foundation: peak lid deflection of 1.9039 mm and aluminium 5052 tip deformation of 0.014133 mm — Figure 10: Displacement results, plywood foundation. Top: lid, max 1.9039 mm. Bottom: aluminium 5052, max 0.014133 mm.

6. Assumptions and limitations (public)

This public summary omits detailed model construction, meshing, material-property sources, pressure mapping, solver controls, and appendices. Results are presented for communication purposes and are not intended to substitute for project-specific engineering sign-off for third-party installations. For full technical documentation and verification, contact Air Vision Systems.

Full technical report available under NDA.
The complete engineering report, including detailed calculation data, modelling assumptions, source figures, appendices and supporting technical evidence, may be made available to approved AVS partners, wholesalers, installers, commercial customers and authorised review parties under a signed non-disclosure agreement.