Rugged Solutions High in the Sky

AMSA Challenger 604 – The next generation in search & rescue aircraft.

Cobham SAR Services Pty Ltd (Cobham), now owned by Leidos.  Entered into a new contract with the Australian Maritime Safety Authority (AMSA) to provide and operate the next generation of dedicated fixed wing aircraft to meet Australia’s search and rescue responsibilities. Under the 12 year contract Cobham has acquired and modified four Challenger 604 jet aircraft to provide a search and rescue capability over land and sea. Based on past successful collaborations, Cobham selected APC Technology as a partner in the project to assist in the design development and manufacture of elements of the all-important mission management system.

Building on a strong history of collaboration and proven engineering success, Cobham selected APC Technology as a trusted partner to support the design, development, and manufacture of key components within the mission management system. This partnership highlights APC Technology’s expertise in delivering rugged, defence-ready computing solutions tailored for high-performance aerospace applications.

The new aircraft significantly enhance airborne search-and-rescue tasks with faster response times, extended range and considerably longer presence on scene in Australia’s search and rescue region using the latest generation search sensors and providing much-advanced communications with AMSA’s Joint Rescue Coordination Centre in Canberra.

In addition, the integration of modern avionics and mission-critical systems reinforces the aircraft’s capability to operate in extreme and remote environments, ensuring reliability when it matters most.

Key features

The Challenger 604 aircraft is faster than the previous aircraft with greater range and endurance. The aircraft has been fitted with latest generation sensors, high-vision windows and a SAR stores delivery system for aerial delivery of life saving equipment.

The aircraft’s mission management and communications system is state-of-the-art with broadband satellite communications allowing real time sharing of streamed video, audio and imagery between the individual aircraft and AMSA’s Joint Rescue Coordination Centre from anywhere within Australia’s search and rescue zone and beyond.

A key highlight of the platform is its state-of-the-art mission management and communication system, which incorporates broadband satellite communications. This enables real-time transmission of high-definition video, audio, and imagery between the aircraft and AMSA’s coordination centre, regardless of location within Australia’s vast search and rescue zone or beyond.

Such capabilities are essential for modern SAR operations, where real-time data sharing, situational awareness, and rapid decision-making can significantly impact mission success.

Cobham’s Mission Systems Manager, John Head, explained the decision to partner with APC Technology:
“We already had an established relationship with APC Technology from previous projects and value their flexible and innovative approach to system design.”
He further highlighted APC Technology’s growing engineering capabilities and investment in advanced manufacturing technologies such as 3D printing, which played a crucial role during the development process. Rapid prototyping allowed teams to physically assess components early, enabling faster design iterations and improved integration within the aircraft systems.
This agile approach not only reduced development timelines but also ensured that all components met strict aerospace standards and end-user requirements.
Corey Smart of APC Technology added:
“We have over 40 years’ experience of supplying custom-built, defence-ready equipment.”
APC Technology’s extensive experience in delivering high-performance, durable, and cost-effective rugged computing solutions ensures that clients like Cobham receive reliable systems capable of operating in the most demanding environments. Their ability to combine deep technical expertise with innovative engineering practices enables them to meet the evolving needs of defence, aerospace, and mission-critical industries.
The contract delivered by APC Technology for Cobham (Leidos) included the design and manufacture of advanced hardware components, such as panel PCs, high-definition displays, Ethernet switches, routers, and specialised enclosures for video and audio processing systems.
Additionally, the mission management system—one of the most critical elements of the aircraft—was developed through a strategic partnership between APC Technology and Acacia Research, an Adelaide-based software company specialising in advanced surveillance systems and high-fidelity simulation technologies.
This collaboration ensured the delivery of a fully integrated, high-performance system capable of supporting complex SAR missions, enhancing operational efficiency, and improving overall mission outcomes.

“We already had an established relationship with APC Technology from previous projects and value their flexible and innovative approach to system design. We have also seen them develop their engineering and manufacturing capabilities which have created a range of benefits during the project cycle.”

Mission Systems Manager, Cobham.