Santa Ana company produces massive parachutes for Orion using a century-old Singer sewing machine.

Ben Tutt, a veteran in parachute design and former warhead modeler, leads a specialized team at Airborne Systems located in Santa Ana, California. Although Tutt has never participated in a parachute jump himself, he emphasizes that practical experience in jumping is not a necessity for his role as the director of engineering, space, and recovery at the aerospace company.

Under Tutt’s direction, a diverse group of 30 engineers and hundreds of sewing machine operators collaborate in manufacturing high-quality parachute systems. The facility occupies 160,000 square feet along Segerstrom Avenue, where intricate designs are crafted from advanced materials, including nylon and Kevlar. These parachutes are engineered for various applications, such as securing space capsules upon their return to Earth and performing crucial military drops.

Tutt’s contribution to the aerospace industry is notable, particularly in the design of complex parachute systems for NASA’s Artemis II Orion spacecraft. This mission involved an 11-parachute sequence aimed at ensuring a safe splashdown. As the Orion capsule descended, Tutt monitored its parachute performance from a distance, reflecting on the significant responsibilities attached to his work.

Airborne Systems, a subsidiary of the aerospace manufacturing giant TransDigm Group based in Cleveland, has a rich history dating back to its founding in 1919. Initially named Irving Air Chute Co., the company faced early financial constraints, and to this day, the original misspelled name remains part of its legacy. Over the years, the company has shifted operations multiple times before consolidating its resources in Santa Ana in 2003.

In addition to its contributions to space missions, Airborne Systems specializes in military parachutes, having manufactured over 60,000 units of the T-11 model for the U.S. Army since 2010. The factory’s operations are complemented by a wide range of machinery, including an antique four-needle Singer sewing machine, which is pivotal to producing the enormous parachutes required for space missions.

The company is recognized for its versatile range of parachute systems, serving multiple clients across different industries. Proposals for high-stakes parachute systems have attracted attention from notable figures like Elon Musk and former NASA Administrator Jared Isaacman. Today, Airborne Systems continues to innovate, developing parachutes for projects that include SpaceX’s Dragon capsule and Blue Origin’s New Shepard rocket.

With projected revenues between 0 million and 0 million, Airborne Systems employs approximately 360 people in Santa Ana and another 175 in Pennsauken, New Jersey. As the company navigates the complex demands of aerospace technology, it remains committed to excellence in parachute manufacturing, ensuring the safety and success of both military personnel and space exploration initiatives.

For further insights into Airborne Systems and its contributions to the aerospace sector, please visit the company’s official website.

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