Aerospace CNC machined parts play a key role in the aerospace industry and help produce critical components for aircraft and spacecraft. Let’s explore the applications, materials and common challenges encountered in aerospace CNC machined parts.
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Aerospace CNC machined parts play a key role in shaping the modern landscape of aviation and space exploration. Their applications span critical components that help improve the functionality and performance of aircraft and spacecraft.
Here is an overview of the various applications:
CNC machining is widely used to manufacture structural parts that are critical to the integrity and durability of aircraft. This includes fuselage components, wing structures, and complex landing gear components.
Precision CNC machining is integral to the production of complex engine components. From turbine blades to combustion chambers, CNC machining ensures that components are manufactured to withstand the extreme conditions of aircraft engines.
Avionics are electronic systems used on aircraft that rely on CNC machining to produce precision parts. This includes control panels, sensors, communications equipment, and other electronic components that are critical to navigation and communication.
CNC machining is an integral part of the manufacturing of spacecraft components. This covers everything from satellite components to propulsion system elements that support exploration and communications beyond the Earth’s atmosphere.
Landing gear is a critical component for the safe takeoff and landing of aircraft, and its precision components are precisely manufactured using CNC machining to ensure reliability and durability in the challenging aerospace environment.
CNC machining is used to manufacture aircraft structures, such as wings and tails, as well as airfoils such as wings and propellers. These components are critical to the aerodynamic performance of aircraft.
CNC machining plays an important role in the production of satellite components, including structural elements, communications systems, and scientific instruments. The accuracy of CNC machining is critical to the successful operation of satellites in orbit.
CNC machining helps manufacture components essential to propulsion systems, including rocket engines in spacecraft. This includes the manufacture of nozzles, thrust chambers, and other complex components.
The application of CNC machining parts in aerospace highlights its importance in ensuring the structural integrity, functionality, and overall performance of aircraft and spacecraft. The precision and reliability achieved through CNC machining contribute to the safety and success of the aerospace industry.
The aerospace industry requires materials that can withstand extreme conditions while providing the strength, durability, and lightweight properties necessary for aircraft and spacecraft. CNC machining in the aerospace industry relies on a range of specialized materials.
The following are commonly used key materials:
Titanium and its alloys are known for their excellent strength-to-weight ratio and are widely used in aerospace CNC machining. These materials are highly resistant to corrosion and are critical for both aircraft and spacecraft components.
Aluminum alloys are favored for their light weight and versatility. Aluminum alloy CNC machining is very common in aerospace applications, especially when producing parts where weight is a key factor.
Stainless steel is chosen for its corrosion resistance and durability. Although slightly heavier than titanium and aluminum, stainless steel is valuable in aerospace components that require enhanced strength and resistance to environmental factors.
Specialized high performance alloys such as Inconel and Monel are used in CNC machining aerospace components in extreme temperatures and corrosive environments. These alloys have excellent heat and corrosion resistance.
CFRP is a composite material consisting of carbon fibers embedded in a polymer matrix. CNC machining is used to mold components to achieve a balance between strength and lightness. CFRP can be used in aircraft structures.
Nickel-based alloys, similar to Inconel, are used in aerospace CNC machining for their high temperature resistance and excellent mechanical properties. These alloys are often used in components exposed to high temperatures, such as jet engines.
Certain copper alloys are used in specific aerospace applications where electrical conductivity is a key factor. CNC machining is used to mold copper components for avionics and electrical systems.
Some aerospace components, especially in non-structural and non-critical applications, are made of high-performance plastics and polymers. CNC machining is used to precisely shape these materials.
The selection of the right material for aerospace CNC machined parts depends on the specific requirements of the part, including its function, environmental exposure, and weight considerations. The combination of these materials with advanced CNC machining technology ensures that parts that meet the stringent requirements of the aerospace industry are produced.
Aerospace CNC machining involves complexity and precision, and challenges are inevitable.
The following are common problems faced in the manufacturing process of aerospace CNC machined parts and effective solutions:
Challenges: Aerospace CNC machined parts often require extremely tight tolerances, which poses a challenge for precision machining.
Solutions: Utilize advanced CNC machines with high-precision capabilities. Regular maintenance and calibration are essential to maintain accuracy. Implement in-process checks to ensure that tolerances are always met.
Challenges: A variety of specialized materials are used, each with unique processing characteristics.
Solution: Use cutting tools and machining strategies tailored for each material type. Work closely with material experts to optimize cutting parameters and tool selection based on material properties.
Challenge: Complex part geometries need to be machined.
Solution: Implement multi-axis CNC machining to machine parts from multiple angles. This allows for machining of complex contours and intricate features in a single setup, increasing efficiency and accuracy.
Challenge: Excessive heat generated during machining can affect material properties.
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Solution: Optimize cutting speeds to effectively control heat generation. Use high-performance tool coatings and use appropriate coolants to dissipate heat. Continuously monitor machining parameters to help prevent overheating.
Challenge: Ensure the highest quality standards for aerospace CNC machined parts.
Solution: Implement a rigorous quality control process. Perform inspections at multiple stages of production, including in-process inspections and final quality inspections. Utilize advanced metrology tools for precise measurements.
Challenge: Tools can wear or break due to the demanding nature of aerospace materials.
Solution: Implement a proactive tool maintenance program. Regularly inspect tools for signs of wear and replace before they reach critical failure points. Use high-quality tool materials and coatings to extend tool life.
Challenge: Manage chips generated during machining, especially in materials prone to chip formation.
Solution: Optimize cutting parameters to control chip formation. Implement effective chip evacuation systems to prevent chip accumulation. Select cutting tools designed for improved chip control.
Challenge: Some materials may exhibit challenging machining behaviors, such as work hardening or thermal sensitivity.
Solution: Select cutting tools designed for challenging materials. Adjust machining parameters to mitigate issues such as work hardening. Work with material experts to understand material behavior and optimize machining strategies.
Addressing these challenges in aerospace CNC machining requires a holistic approach that combines advanced technology, expertise, and continuous process improvement. The integration of innovative solutions ensures the continued production of high-quality aerospace CNC machined parts.
One of the drivers in our success is through experience and rigorous development of digital manufacturing tools. We have found the right blend of working with autonomous digital tools and hands-on application engineers to meet aerospace demands.
When starting the digital manufacturing process with many manufacturers, it can be easy to upload a CAD file into multiple online quoting tools.
Unfortunately, some manufacturers' online quoting tools don’t take into account all of the back-end requirements, or offer all of a manufacturer’s processes. This is where we choose to be upfront so that each step required for the part or project is reflected in the initial quote.
When using online digital tools, quoting software can greatly accelerate development and production cycles.
However, to get the most out of these tools, make sure you are working with software (and a manufacturer) that includes the following:
A major challenge in the aerospace and defense industry is on-time delivery and quality. Industry sources say around 80% of orders generally show up on time. Yet, when those orders do show up on time, about 25% of parts do not meet the required quality. A common complaint from aerospace companies is when vendors promise a lead time with a cheaper price but could not deliver within the timeline quoted. Delays have led to missed deadlines and greater costs to fix than if they would have just started with the higher-priced vendor.
Our online, interactive quoting system turns your CAD model into a quote with immediate design analysis and feedback. Your design can be reworked to determine the ideal balance of processes, materials, time, and cost. This greatly increases efficiency as it isn’t necessary to talk with someone every time a part is needed. But when you need a knowledgeable person on your side, we have a team of applications engineers ready to back up our automated tools. All contacts, customer or not, get free access to our responsive team that understands how to design for our processes, reduce cost, and answer a myriad of other technical questions.
You may want to reduce overall components in a part or product design for several reasons.
First, lightweighting is crucial in aerospace. Companies know just how many ounces of fuel it takes to fly a gram of weight in flight, for example, so slight reductions drive major gains. The choice of materials, and sometimes the method of manufacturing, also factor into this lightweighting equation. But trimming part count helps, too.
Second, cutting costs is important. Plastics and metals can be expensive, and so can assembly time. Accordingly, if designs can lessen the number of components or parts, this can reduce materials and assembly time.
With these lightweighting and cost considerations in mind, which materials work best for aerospace components? Titanium is often a go-to choice, available through machining and 3D printing services. This lightweight and strong material offers excellent corrosion and temperature resistance. Aluminum, and its high strength-to-weight ratio makes it a good candidate for housing and brackets that must support high loading. Aluminum also is available for both machined and 3D-printed parts. Inconel, a 3D-printed metal, is a nickel chromium superalloy ideal for rocket engine components and other applications that require high-temperature resistance. Stainless steel also is a frequent materials choice. For example, SS 17-4 PH is used in the aerospace industry due to its high strength, good corrosion resistance, and good mechanical properties at temperatures up to 600 degrees F. Like titanium, it can be machined or 3D printed. Liquid silicone rubber is also widely used in the industry. This elastic fluorosilicone material is specifically geared toward fuel and oil resistance while optical silicone rubber is a good PC/PMMA alternative. Common applications in aerospace include soft-touch surfaces, gaskets, seals, and O-rings.
Finally, beyond lightweighting and cost cutting issues, the aerospace industry faces unique benefits and challenges with high risks and rewards. Companies are concerned with development cycles, prototyping, hot-fire testing, and production. So, while component reduction can help reduce part weight and assembly time, the real savings are in the reduction of the headaches and overhead associated with the supply chain and paper trail for each part. In aerospace, each component that goes into the final product has a tremendous amount of validation behind it such as material traceability, shock and vibe tests, rigorous inspections, and much more. In such a regulated industry, reducing parts can provide great value by reducing inventory, having fewer documents to track, and streamlining your supply chain.
If you have an internal machine shop but have to deal with a lot of different types of manufacturing in a small space, you might have taken projects to outside vendors for development work. It is important to find the right vendor with the capacity to meet your high demands for quality and speed. You may know but it bears repeating that there are no universal processes or materials. You need all the tools in your arsenal to find the best solutions to stay on the cutting edge. Therefore, work with companies that are able to offer a range of manufacturing processes and materials. We offer CNC machining, sheet metal fabrication, injection molding, and six different industrial-grade 3D printing (additive manufacturing) methods. Additionally, you can choose from hundreds of commercial-grade plastics, metals, and elastomers that are suitable for both prototyping and production. See our Materials Comparison Guide for a complete list.
We use multiple additive processes: stereolithography, direct metal laser sintering (DMLS), selective laser sintering, Multi Jet Fusion, Carbon DLS, and PolyJet. DMLS has proven to be a desirable process in the aerospace industry because it offers:
DMLS does have a limited build space. However, we also offer large-format metal parts. We can build production-grade metal parts as large as 31.5 in. x 15.7 in. x 19.7 in. (800mm x 398mm x 500mm). We are initially focusing on Inconel 718 as a material to use to better serve the demand for larger complex parts in the aerospace industry. This large-format metal 3D printing, from our GE Additive Concept Laser X-Line machine, also is an example of how our company is technology agnostic, using machines, equipment, and processes sourced from a variety of companies.
Beyond the manufacturing methods referenced (subtractive and additive), we also offer a number of secondary or finishing options, if your design calls for these applications:
If you need several vendors for different processes or secondary processes, remember the benefits mentioned earlier about using one supplier with multiple processes. We offer many processes and materials while operating as a local vendor to reduce time and costs.
In addition, as we recently noted in our trend report on aerospace manufacturing, often the best solutions for aerospace and defense will involve a hybrid approach using multiple technologies in concert. Just as a traditional toolbox contains both hammer and pliers, so too do today’s advanced manufacturing operations house both additive and subtractive manufacturing systems and know-how.
Finally, aerospace product designers and developers need to carefully navigate government and safety policy and compliance issues. Working in such a highly regulated industry, it is important to find vendors familiar with aerospace requirements. Traceability, documentation, testing, and certified parts that are USA/ITAR compliant in an ISO environment can decrease much of the work needed to be done, tested, or verified in house.
Governing bodies are continuously working on standards for additive manufacturing, so knowing exactly what is needed may be difficult to find for non-traditional processes. However, standards or certifications for finished parts apply no matter how it was manufactured. You will want to make sure vendors have certified materials, powder analysis, material traceability, and more depending on your needs.
We have already invested heavily in digital manufacturing methods to provide you with automated tools, documentation, testing, and traceability, all supported by our applications engineers, delivering you a streamlined and efficient digital thread. We offer the following quality documentations and report options in an ISO , AS certified, USA/ITAR compliant environment:
Ultimately, we will work with you to find the best solution and consider all steps of your project. If you would like more information, contact our applications engineers at 877-479-, us at [ protected], or start your design today by uploading your 3D CAD model to receive an interactive quote within hours.
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