The aerospace sector is one of the most complex industries in the world, with a global market worth more than $800 billion. Aerospace machining companies play an integral role in manufacturing parts for every aircraft or spacecraft, ensuring safety by meeting strict international safety standards. Precision machining and proper assembly of these components turn this collection of parts into aircraft that take off and land vertically, commercial airliners, smaller aircraft, spacecraft, or other machinery made to fly.
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Aerospace machining companies are key to making mechanical flight safe and reliable, so their work must maintain a level of precision not needed in most other industries. Sometimes, this means working with tolerances as small as a tiny fraction of a millimeter. To achieve these extraordinarily close tolerances, much of today’s aerospace machining is automated to guarantee consistency. However, this precision must be verified and documented to meet strict regulatory requirements and industry standards.
Aerospace machining companies must ensure that any components they manufacture comply with AS certification. This standard requires specifications concerning the design and assembly of aerospace parts into their final form, whether an aircraft or spacecraft. Aerospace machining often utilizes automation directed by CNC technology to achieve these stringent requirements. Used widely for fabricating parts for the aerospace industry, CNC machining entails an automated process of subtractive manufacturing that takes a block of material and turns it into a precision-machined part.
Aerospace machining companies use CNC technology to produce parts for:
Aerospace machining companies use CNC technology to achieve greater accuracy in their parts. With CNC machining, manufacturers can pre-program equipment with exact instructions concerning how the tooling moves and fabricates workpieces. This helps lower the chance of inconsistencies and errors in aerospace machining operations and aids in fabricating complex designs that vary in size and shape. Additionally, the automation provided by CNC machinery allows aerospace machining companies to handle shorter lead times and meet larger orders.
When thinking about aerospace machining, most people consider major components like an aircraft’s engines or wings. However, consider the largest passenger airliner in the world, the Airbus A380, which has four million distinct components made by companies in thirty different countries globally. Though not all of these parts are fabricated via automated aerospace machining techniques, most metal components are.
When it comes to materials used in aerospace machining, companies need to consider strong yet lightweight metals. As such, steel components are generally undesirable, as they’re much heavier, which makes them detrimental to the fuel efficiency of an aircraft. For this reason, most alloys used for aerospace applications involve aluminum or titanium. As such, AS certification also applies to the vendors of the metals used for aircraft components and not just aerospace machining companies.
CNC technology used in aerospace engineering can handle both metals (and their alloys) quite well. Titanium is an extremely strong metal that’s half as light as steel but 30 percent stronger, offering excellent corrosion and heat resistance. This makes titanium and its alloys the best material for aircraft engines, landing gear, and other external and critical components. While only half as strong, aluminum is much less dense (titanium is 66 percent denser) and more cost-effective than titanium. Its lighter weight makes it very suitable for aerospace machining.
The exceptional complexity of machining parts for the aerospace sector means dealing with intricate geometries, for which advanced solutions involving CNC machines are ideal. Modern multi-axis machinery that uses CNC technology works well for aerospace machining. CNC machinery’s accuracy allows for more innovative designs that are increasingly common in modern aircraft. In the 21stcentury, aerospace machining techniques often utilize 5-axis CNC machines, which have become a basic tool for machine shops making parts for this industry.
5-axis aerospace machining permits pivoting on five axes at once, which enables machine shops to fabricate markedly complex parts more quickly. CNC machining processes let aerospace machining companies create intricate designs for aviation components that fit precisely with other parts. Aerospace machining using 5-axis CNC technology allows the making of workpieces with incredibly intricate geometries, while CNC machines can be continuously reconfigured should designs change.
The AS standard was developed to meet the unique needs of the aerospace industry and make aircraft more reliable and safe. Though local regulations may differ, aerospace machining companies must have this certification to access the sector globally. AS certification focuses on product safety, managing risk, and emphasizing the need for consistency in aerospace components throughout their lifespan. This standard also applies to the defense sector, which may open up even more opportunities for aerospace machining companies.
AS certification builds upon ISO , a global quality management standard widely recognized in other sectors. To work with organizations like the European Aviation Safety Agency (EASA), Federal Aviation Administration (FAA), and National Aeronautics and Space Administration (NASA), AS certification is normally necessary. By obtaining AS certification, aerospace machining companies exhibit their dedication to fabricating quality aviation parts, which augment safety in the sector.
Aerospace machining companies with AS certification will have established a quality management system that they support and continue to improve upon. As a result, their components will have fewer defects while ensuring their processes are more efficient. Along with these aspects regarding AS-certified aerospace machining companies, there are special requirements concerning communications and training of employees. This will, in turn, result in better customer service and more satisfied clients.
While following this standard will help augment the quality of products and services, AS certification helps aerospace machining companies follow local, regional, and global regulations, along with many countries’ aerospace legislation. AS certification helps aerospace manufacturers stand out from competition that isn’t certified. For smaller machine shops looking to break into the aerospace market, following these standards helps them compete against larger aerospace machining companies.
In today’s manufacturing landscape, precision machined metal parts play a vital role, particularly in sectors with strict standards and complex designs. This is especially true in aerospace, where safety, performance, and reliability are of utmost importance. Precision machining enables the production of intricate metal components with micron-level tolerances, ensuring that aerospace systems operate seamlessly, even under extreme conditions.
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The aerospace sector depends on high-performance components — such as turbine blades and landing gear — where even minor deviations can affect performance. With recent advancements in precision machining, manufacturers can now produce parts that consistently meet the industry’s rigorous quality standards, driving aerospace technology to new levels.
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The importance of precision machined metal parts in aerospace cannot be overstated. Aircraft and spacecraft operate under some of the most extreme conditions imaginable, from constant wear and tear and intense internal heat, to pressure from high-altitude flight and extremely cold external temperatures. Facing these pressures, even a slight flaw in a given component can lead to disastrous failure. Precision machining helps ensure that each aerospace part meets the tight tolerances necessary for optimal performance, reliability, and safety.
Some of the many precision machined metal parts in aerospace include:
By delivering high-precision parts, aerospace manufacturers can trust that every component will perform optimally, contributing to safer and more efficient flights.
Precision machined metal parts offer several advantages that directly contribute to the success and advancement of aerospace technologies:
Precision machined metal components are essential for optimizing aerospace system performance. Parts like turbine blades, which maximize thrust, and streamlined structural elements that reduce drag, rely on meticulous manufacturing to function precisely as intended. This precision boosts overall system efficiency, allowing aerospace engineers to design high-performance aircraft with improved speed, fuel efficiency, and aerodynamics.
Reliability in aerospace is a strict requirement. Precision machined metal parts meet rigorous quality standards, significantly reducing the risk of failure in critical systems. This reliability allows engineers to innovate confidently, pushing design boundaries while adhering to essential safety and regulatory standards.
While precision machining involves upfront costs, it often leads to significant long-term savings. By minimizing waste and reducing the need for rework, aerospace manufacturers can control production costs while ensuring quality across high-volume runs. These cost efficiencies enable reinvestment in research and development, advancing next-generation aerospace technologies.
Aerospace often demands highly customized solutions, and precision machining enables the production of specialized components tailored to unique applications. This flexibility encourages engineers to experiment with new designs and materials, paving the way for transformative advancements in aerospace technology.
Manufacturing precision machined metal parts presents a unique set of challenges; addressing them requires advanced technology, expertise, and meticulous attention to detail. For instance, aerospace components need to be machined to incredibly tight tolerances, sometimes within microns. Any deviation can compromise system performance and safety. To overcome this, manufacturers use cutting-edge CNC machines, real-time monitoring, and advanced measurement techniques to maintain consistency across production.
Many aerospace components also have intricate shapes that are difficult to machine, such as turbine blades or some structural components. With 5-axis CNC machining and advanced CAD/CAM software, manufacturers can machine even the most complicated designs while maintaining high precision.
By taking on these challenges with advanced technology and expert craftsmanship, manufacturers can produce high-precision aerospace components that meet the industry’s demanding standards for quality and performance.
For decades, Re:Build Cutting Dynamics has been a trusted partner for the aerospace industry, providing precision metal fabrication, CNC machining services, hydroforming, hot forming titanium services, and much more that meet the highest standards. Our experienced team delivers reliable, high-performance solutions tailored to the demanding needs of aerospace applications.
Contact us today to learn how we can support your next aerospace project.
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