How Are Aerospace Parts Manufactured?

The quick answer to the question: “How are aerospace parts manufactured?” is “very precisely and with much oversight”. The industry is regulated by many U.S Government regulations. Not only pertaining to the function of the industry in its service to the public, but to the actual aerospace components, like nuts and bolts. There is no part in any aircraft that does not have a specific method to produce, material to use and the precision required for its optimum performance. Aerospace companies rely on partnerships with outside manufacturing service providers. Together they form a bonding relationship that proceeds on the notion that it is in the public and employee’s safety that regulatory standards are governed by such as the FAA or Federal Aviation Administration, FAR or Federal Aviation Regulations, SAE or Society of Engineers and Aerospace Standards, AS9100 or Aerospace Quality Management System Standard and others. Machining aerospace parts can be very satisfying to the countless individuals involved. To give a number there are about 1 million workers just in aerospace and they contribute to about 900 billion in sales revenue for the United States. The process of manufacturing can be long and at times seem tedious, but all is for the safest and pleasurable experience the public can receive. A review of how precision aerospace components are manufactured is:

• Concept, Design and Engineering-The ideas come forward for breakthroughs in aerodynamics or perhaps for a better arm rest. Each idea goes to engineering groups of mechanical, electrical, materials, metallurgy, chemical disciplines, and many others. With computer aided design or CAD CAM software, 3D models are made, and evaluations performed.
• Material choice- For structural parts, materials like aluminum, titanium or steel are used. But there may be other areas where composite materials are best. There may be a need for a gasket or the use of new adhesives and epoxies. All will go through critical review before the correct choice is made.
• Manufacturing methods- Once the concept is approved and the material selected, there will be a phase for research and development or R&D. This can be many months or perhaps years of testing and evaluation. Once the testing phase is done and the machining of aerospace parts is approved, Production manufacturing can take place. Aerospace machinists will use manufacturing methods such as:
• CNC Drills-Used to create holes, slots, and other geometry. Cutting through or programed depths.
• CNC Lathes– Rotating the material while tooling inserts cut the shape. Good for cylinders and similar shapes.
• CNC Milling– Used in 3,4, and 5 axis machines. Can produce very complex parts.
• CNC Routers– Sheets of materials are cut and drilled by this method.
• CNC Laser Cutting– Also good for cutting sheets of materials, especially in thinner gauges.
• CNC Plasma Cutting– Used for industrial applications and can cut many material types.
• CNC Threading– To produce precision threads for screws, bolts, rods and other parts where secure and precise connections are needed.
• CNC Waterjet-Using high-water pressure and abrasives can cut various materials with no heat affect.
• Quality Control– All parts whether manufactured for aerospace components, the medical or oil and gas industries to name a few, will have quality levels that the manufactured parts must meet. The tolerances that these components require vary per the use and environments that they will be subjected to. A standard tolerance may apply to something neither critical nor structural and might be held to a +/- ( ±0.025 mm or less). A mid-level tolerance may be asked to hold parts to a +/- ( ±0.005 mm to ±0.0125 mm) and a critical or tight tolerance may be held to a +/- ( ±0.0005 mm to ±0.0025 mm).

• Finishing- Some parts may need a finishing process to add more protection from wear or to prevent rust and corrosion. Aerospace machinists will use anodizing, powder coating, electroplating as methods to finish a part.

Once assembled and the selected parts are in use, a precision aerospace company works diligently to review and replace parts on a scheduled plan, often before the estimated life span of the part is met. This is to ensure that the operation of the aircraft and all the supporting subsystems perform flawlessly and, in the end, give passengers confidence in these well-managed systems resulting in satisfaction from the experience and continued patronage.