<![CDATA[The reliability of aircraft ice protection systems is crucial for flight safety, especially at high altitudes with extreme temperatures. One vital component is the inlet cowl thermal anti-icing pressure switch on the Boeing 737-300, which monitors bleed air pressure and activates the cockpit indicator at 65 ± 3 PSI. At Asia Cargo Airlines, functional checks are still conducted manually using jumper wires, masking tape, and a 28V DC lamp, requiring three technicians, being inefficient, and carrying significant risks. This study aims to design a dedicated bench test device for precise, safe, and standard-compliant inspection of the pressure switch. The research employed a Research and Development (R&D) method combined with the systematic engineering design approach VDI 2221, including clarification, conceptual design, embodiment, and detailed design stages. The developed tool consists of a pressure system (¼ inch hose, ball valve, pressure gauge up to 100 PSI) and an electrical system (3-pin connector, 24V DC supply, indicator lamp). Test results show that the device operates within the specified range of 62–68 PSI without leakage or malfunction. Validation by three expert evaluators rated the device as “highly feasible” with scores above 85%. The tool proved more efficient, safe, and faster, requiring only one technician and reducing test time from 30 to 15 minutes, thereby enhancing safety and maintenance efficiency for the Boeing 737-300.]]>
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