Machining for aerospace and aviation hardware
Aerospace parts are judged twice: once by the drawing, and once by the paper that proves the drawing was met. Thin walls, 5-axis surfaces and traceability are the three things that separate this work from ordinary precision machining.
What we machine
7075 and 6061 structural parts pocketed to remove mass from the neutral axis. The machining risk is distortion: a thin frame released from a billet moves, so roughing, stress relief and finishing are separate steps.
Seat components, armrest brackets, panel mounts and trim hardware. Usually 6061 or 5052 with anodizing or powder coating, and a visible face that must not carry tool marks.
Brackets, covers and ducting supports around the engine bay, where titanium or stainless may be specified for temperature rather than strength. Titanium machines at a fraction of the aluminium rate, and the quote reflects it.
Test rigs, mounting frames and check fixtures. Short runs, fast turnaround, and dimensions driven by the article under test rather than by a drawing standard.
Airframe plates, arm joints and payload mounts where 1.5 mm walls are normal. Mass is inspected as well as dimensions, because a heavy airframe costs endurance.
Materials and what they cost in cycle time
| Material | Strength | Machinability | Note |
|---|---|---|---|
| 6061-T6 | 310 MPa | Excellent | Baseline; most brackets |
| 7075-T6 | 572 MPa | Good | Structural parts, anodizes darker |
| 2024-T351 | 470 MPa | Good | Fatigue-critical, corrosion needs protection |
| Ti-6Al-4V (TC4) | 950 MPa | Poor | 3–5× the cycle time of aluminium |
| TA2 titanium | 345 MPa | Fair | Corrosion resistance, formable |
| 17-4 PH | 1,100 MPa | Fair | Strength plus corrosion, distorts on aging |
Traceability and inspection
Aerospace buyers ask for the same three things every time: which heat lot the material came from, which dimensions were measured and how, and who signed the report. Those are answerable without a certified quality system, and they are what an incoming inspection actually uses.
Where a full dimensional layout is required, it is built around the drawing's callouts and GD&T frames, measured on a CMM with the stated datum scheme. Where only critical features matter, the report says so explicitly instead of implying a full layout.
| Profile of a surface | 0.05–0.1 mm on 5-axis surfaces |
|---|---|
| Wall thickness | ±0.1 mm, verified by ultrasonic or CMM |
| Hole position | Ø0.1 mm, often with a fastener fit callout |
| Flatness | 0.05 mm on mating faces |
| Traceability | Heat lot on the material cert, matched to the batch |
What we do not claim
We machine to the drawing and provide the measurement evidence. We do not hold AS9100 or a NADCAP process approval, and we will not imply otherwise. If your programme requires an approved supplier list entry, that has to be resolved before the first order.
Heat treatment, non-destructive testing and plating are performed by suppliers with their own approvals. We coordinate them and ship the certificates, but the approval belongs to that supplier, not to us.
Industry questions
On a well-supported surface in aluminium, yes. On a thin titanium wall the deflection during finishing is the limit, so the answer depends on the part and is confirmed at DFM rather than promised generically.
Yes, on request. The mill certificate carries chemistry and mechanical properties and is matched to the batch, so a traceability question can be answered months later.
Yes, Grade 2 and Grade 5. Expect three to five times the cycle time of the same geometry in aluminium, and design with generous radii because thin titanium walls spring back.
Yes. SGS, BV, TÜV or your nominated inspector can attend before dispatch, which is usually cheaper than discovering a problem after the parts have flown.
Send the structural part with its datum scheme.
The quote will say which callouts drive the fixture, where distortion is likely, and whether the wall thickness is achievable in the specified alloy.
From the shop notes
Longer answers to the questions these pages raise.