Aerospace manufacture blog

Aerospace Manufacture 

One of the largest industries leveraging wholesale application of composites is aerospace and aviation. The benefits that composites bring to aerospace manufacture are many. Composites hold the key to a plethora of extraordinary properties and benefits. Light in weight, yet having exceptional strength, high density to stiffness ratios, higher resistance to corrosion, production of complex shapes, the list goes on. At the top of the pyramid, however, weight reduction gains are the single biggest incentive in aerospace manufacture. Together with weight reduction, are many operational advantages which when combined with delivering enhanced performance criteria, makes composites the material of choice in aerospace manufacture.  

Freeform Technology remain at the forefront of composite tooling and design. Nurturing a proven history of success, gained over many years working with high octane race cars and Formula1. Creating an obvious parallel with the leading-edge aerospace and aviation industries. Freeform Technology having worked with several of the leading F1 teams, shared in many successes on the racetrack.  As a result, it’s been a natural evolutionary transition to use this knowledge and experience in directly applying this expertise and applied excellence to the high-performance aerospace industry.  

The increased number of metal components being exchanged – like for like – with composites, serves to ensure composites will be the obvious material of choice in the near and foreseeable future in relation to aerospace. Composites in aviation vary from small micro parts, up to and including fin and tail assemblies. It’s not just commercial airliners either, aerospace manufacture, also extends to include satellites, military jets, helicopters, and space exploration. Even more reason is the aspirational net zero aviation goal set to be achieved by 2050. The race is on. Composites used in aviation create considerably lighter aircrafts, indirectly contributing to the ambition of carbon reduction. Predominantly achieved through reduced fuel consumption. With 2050 as the goal deadline, composites used in aerospace manufacture look set to continue to increase substantially. Another additional factor, and probably a less well-known fact, is that already, production of one of the latest commercial airliner designs coming off the drawing board has a construction made up of around 50% composite! 

So, it should come as no surprise that innovation, industry transition and market disruption are the three key drivers Freeform Technology are responding towards. Our approach is focused towards supporting customers and industries seeking a trusted partner, one who can offer the supply and provision of engineering services, solutions, design excellence, and subject matter expertise for aerospace manufacture and associated industries. 

Materials 

We machine a variety of tooling substrates, these include: 

  • Epoxy 
  • High density polyurethane 
  • Steels 
  • Aluminium 
  • Carbon Fibre 

Machines 

Our workshop comprises of a host of manufacturing technology, these include: 

  • DMU 5-axis machining centres 
  • CMS 5-axis routers 
  • Latest CAD/CAM from Siemens  
  • Portable measuring arms from Romer and Faro, together with laser scanning capability 

5 axis machines are particularly suited to aerospace manufacture in being able to produce the most sophisticated, complex, and intricate patterns, moulds, and components. Machining capabilities range from micro to larger size projects, and everything in-between.  

Workshop 

We operate an environmentally safe machine shop, inspection department and workshop, one that recognises the specific and unique challenges associated with aerospace manufacture. It’s a production environment that complements our capabilities in providing the very highest levels of engineering competencies to our customers, provides safeguards for our technicians, and creates an environment that facilitates production of the very highest standards in component manufacture and finished product.  

Services 

We offer a full scope of services that provide our customers a full turn-key solution to manufacturing, these can include: 

  • CAD and 3D modelling 
  • Engineering tooling design 
  • Reverse engineering 
  • Precision engineering 
  • Rapid prototypes 
  • Full project management 

People 

We have a multi-disciplined team of experienced professionals holding various industry accreditations and certifications. Our team offer a wide set of capabilities and services to our customers, from conceptual design, right the way through to final finished product. 

Above all else, we offer a personalised approach, founded upon our ethos to create true, authentic working partnerships.  

All with the aim of providing the very best services and solutions to our customers, together with offering increased peace of mind and assurance.     

To understand more about how Freeform Technology can support your aerospace manufacturing requirements, please click the button below.