Manufacturing Process of Components and Assemblies

Multi-Axis CNC Precision Machining

Custom Aerospace Components is a high precision machining facility comprised of state of the art CNC Milling, Lathe, EDM and Grinding Machines. With these machining centers we are capable of holding tolerances to within 50 millionths, finishes to 1 light band, turn components up to 22.00" in diameter X 36.00" long and mill components up to 32.00" x 32.00".

Our CNC Milling, Lathe and EDM Machines are capable of multi-axis machining with spindle speeds up to 25,000 RPM. Utilizing these machining centers our team or Engineers, CNC Programmers and Machinists are able to produce components to stringent specifications.

We pride ourselves on producing quality components to exacting standards which is evident in our ISO9100:2008 and AS9100 certifications.

Concurrent Engineering

Concurrent engineering is a strategy we employ to achieve the best results through the most efficient process. To aid in the development of the process our Engineers and CNC Programs use JobBoss and Mastercam CADCAM. In addition to three-dimensional (3-D) (CAD) models; rapid tooling, rapid prototype, and rapid testing techniques are used. These design technologies are important because of the key information they convey: the 3-D model allows the Engineers and CNC Programs to interpret design features in a more effective and efficient way.

Manufacturing programs and process are closely coordinated to achieve an optimal match of resources in the machine shop for effective cost, quality, and delivery. Decision making involves full team participation and involvement. The team often consists of engineering, manufacturing, purchasing, suppliers, and customers. Collaboration between Custom Aerospace Components its Customers and Suppliers is a key component to the success of concurrent engineering.

Quality Process/Contract Review

Our Quality Process begins with a full contract review of each order which involves our engineering and quality departments. Each component is reviewed for material, process, inspection, marking and shipping requirements prior to release to the machine shop. Once the contract review is complete; process and quality plans are developed to ensure compliance to customer's specification throughout the manufacturing process. During the manufacturing process key characteristics are inspected and records are retained per industry and customer requirements. Upon completion of the manufacturing process a 100% final inspection is preformed and all key characteristics are recorded and retained per industry and customer requirements.

Testing & Inspection of Aerospace Components & Assemblies

We perform first piece, in-process, incoming and final inspections throughout the entire production cycle to ensure the highest quality of every component that Custom Aerospace Components manufactures. All incoming material (raw material, hardware and components returning from an outside process) is thoroughly inspected for material condition, chemical composition and special process specification before it's issued to the machine shop. Our extensive quality department performs a first piece inspection using an advanced Coordinate Measuring Machines (CMM) before each manufacturing process. The finished product is subjected to a 100% final inspection using an advanced Coordinate Measuring Machines (CMM) to ensure that all key characteristics meet the customer's specifications.

In accordance with customer and industry standards all first piece, in-process, incoming and final inspection reports created during the manufacturing process are retained.

Our testing department performs Non-destructive testing processes such as pressure, leak and vacuum testing in accordance with customer's specifications.

Secondary Processing

Custom Aerospace Components has diversified its offerings within the machine shop to include a wide range of in-house secondary processes. Our heat treating oven is capable of heat treating to HT-404 and HT-405. The fabrication department is outfitted with Heliarc, Arc, Oxygen and Acetylene welding and Silver Brazing. We have the expertise to fabricate small complex assemblies as well as large assemblies. The testing department is capable of performing Non-destructive testing processes such as pressure, leak and vacuum testing. Our component marking department uses a Trumph Vector Mark Laser Marking machine to mark components to our customer's specifications.

Keeping these processes in house enables Custom Aerospace Components to better control the manufacturing process throughout the manufacturing cycle.

Supply Chain Management

Implementing Supply Chain Management has enabled Custom Aerospace Components to optimize the flow of information to our suppliers. We meet regularly with our suppliers to flow down all applicable specifications and to eliminate any potential process related issues. The relationships built between Custom Aerospace Components and its suppliers are a key component to the overall success of the manufacturing process in our machine shop. The benefits of these relationships are reduced operational expenses, improved customer service and improved competitiveness. Custom Aerospace Components maintains an approved vendor list where vendors are measured for their quality and on time performance. Vendor review and approval ensures that suppliers selected to provide product and/or services to Custom Aerospace Components employ a quality system that meets the quality requirements of Custom Aerospace Components and its customers.

Inventory Management

Custom Aerospace Components has a diverse and flexible inventory system which is capable of reacting to the demands of our customers. We've worked with systems such as KANBAN, JIT, Kitting, PAC and online procurement systems. Utilizing our machine shop ERP software (JobBoss) we're able to set minimum, maximum and reorder levels for all components and assemblies. If inventory levels reach minimum an automated alert is issued; informing Engineering to release a new production lot to the machine shop for manufacturing. Tracking inventory levels enables us to release economic lot sizes to the machine shop for manufacturing thus reducing our operational expenses and any potential delivery delays to our customers.

Custom Aerospace Components has the ability to adapt our system to the delivery needs of our customers. In some cases we're able to synchronize our customers system with our system therefore reducing administrative expenses and improving the flow of information. Our onsite warehouse enables us to hold product for release according to the customer's needs.

Mechanical Assembly

In our mechanical assembly department the technicians are qualified to perform a wide range of assemblies; form complex to simple two component assemblies. To aid the technicians in the assembly process Custom Aerospace Components creates detailed work instructions to ensure the repeatability and consistent quality of each assembly. In addition to the work instructions; critical gauging and tools are calibrated annually where applicable.

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