Aerospace Manufacturing: AS9100D & ITAR Disciplined Parts
Structural brackets, actuator housings, avionics enclosures, and satellite flight hardware machined and finished under AS9100D with full material traceability and a documented first article report on every new part.
- AS9100D
- ITAR registered
- AS9102 first article
- EN 10204 3.1 mill certs
- DFM with a 48 hour reply
Aerospace capability snapshot
Typical parts we manufacture for aerospace & defense
Most programs in this segment are a mix of structural machined parts, fabricated brackets and electronic enclosures. A single cell produces all three so configuration control stays under one roof.
| Part type | Why we make it this way | Material families |
|---|---|---|
| Aerodynamic and structural brackets | Machined from solid plate or 5-axis from billet to eliminate fastener count and assembly risk | 7075-T7351, 2024-T3, 6061-T6 |
| Actuator and hydraulic housings | CNC milling + turning on one fixture to control bore concentricity | 7075, 17-4PH, Ti-6Al-4V, see titanium capability |
| Avionics enclosures | CNC machined lids and chassis with vent pockets and RF sealing grooves | 6061-T6, 5052, magnesium for weight-critical boxes magnesium alloy capability |
| Engine and propulsion components | Precision milled with material certification back to the mill heat | Inconel 718, titanium, 17-4PH |
| UAV and small-drone frames | Lightweight 5-axis from solid, allowing complex cores and pockets | 7075, carbon-filled engineering plastics |
| Sheet metal avionics chassis | Laser cut, formed and welded to MIL-spec tolerance where specified | 5052, 6061, cold-rolled steel with plating |
Manufacturing route we recommend
- 5-axis CNC machining for monolithic structural parts where fasteners add weight and risk.
- 3 and 4-axis CNC milling for prismatic brackets where 5-axis is not justified.
- CNC turning for rotational features, ports and bushings.
- Wire and sinker EDM for slots, keyways and difficult-to-cut features in hardened materials.
- Sheet metal fabrication for avionics chassis, brackets and guards.
- CMM inspection with AS9102 for the first article on every new part and at defined production intervals thereafter.
Each step in this list is a live link to the matching capability page, so an engineer reviewing the package can trace the process back to the part.
Materials for aerospace programs
Material choice often drives both performance and paperwork. The links below point to our capability pages for the alloys used most often in aerospace flight hardware.
- 7075-T7351 aluminium
- 2024-T3 aluminium
- 6061-T6 aluminium
- Ti-6Al-4V titanium
- 17-4PH stainless
- Inconel 718
- Magnesium AZ31B
- 5052-H32 sheet
View the dedicated capability for titanium at titanium machining and for lightweight structures at magnesium alloy machining.
Surface finishes used on flight hardware
Anodizing & chemical conversion
- Hard anodize Type III (Mil-A-8625)
- Sulphuric anodize Type II (Mil-A-8625)
- Chromate conversion / chem film
- Black and coloured anodizing for identification
Mechanical and chemical
- Passivation to ASTM A967
- Shot peening for fatigue-sensitive areas
- Electroless nickel for wear surfaces
- Dry film lubricant on sliding interfaces
Recent project snapshot
Monolithic structural bracket — 5-axis machined 7075-T7351
An aerospace structural bracket previously assembled from nine sheet metal parts and forty fasteners was redesigned as a single 5-axis machined part. Mass dropped by 22 per cent, fastener count dropped to zero, and the inspection pack dropped from nine first articles to one AS9102 report.
- Process
- 5-axis CNC machining from 7075-T7351 plate
- Tolerance
- ±0.05 mm on critical geometry
- Documentation
- AS9102 Forms 1–3, material cert, surface treatment cert
- Outcome
- Released to serial production in four weeks from RFQ
Frequently asked questions
Are you certified to AS9100D?
Yes. We confirm the current registration number, scope and expiry during quotation so nothing is assumed.
Are you ITAR registered?
Yes. We apply ITAR controls to data handling, segregation and visitor access for any part listed on the United States Munitions List.
What is the typical first article lead time?
For a structural machined part drawing set, first article is generally delivered in two to three weeks from order release. For higher-complexity housings, allow three to four.
Do you issue IMDS entries?
For automotive and EV parts we submit IMDS data. For aerospace we issue the material declaration format requested by the program — typical is the OEM-supplied format attached to the contract.
Can you handle low-volume flight hardware?
Yes. Most of our aerospace orders are 5 to 500 pieces per year. The program strategy is built around your forecast so the fixture and inspection plan scales with the volume.
Tell us about the flight part
Send your drawing and the certification requirements. We will confirm scope, lead time and the inspection pack before quoting.