Aerospace parts aren’t like regular manufacturing work – we’re talking about components that need tolerances within ±0.003″ (±0.076 mm) or tighter, complex shapes that require 5-axis simultaneous machining, and materials that have to handle temperatures over 2,000 °F without failing. Your average machine shop simply doesn’t have the certifications, equipment, or material knowledge to touch this kind of work, and honestly, they shouldn’t be trying.
We run AS9100D-certified operations with multi-axis CNC equipment specifically set up for aerospace demands. That means machining Ti-6Al-4V titanium, Inconel 718, and aerospace-grade aluminum alloys with full traceability and CMM inspection backing up every part. Whether you’re building aircraft or spacecraft components, the tolerances, material properties, and documentation requirements are non-negotiable – and that’s exactly what our setup is designed to deliver.
Key Takeaways
- AS9100D and ISO 9001 certifications mean the quality systems and traceability are actually there, not just claimed
- 5-axis simultaneous machining handles complex geometries in one setup, cutting lead times by 40-60% compared to multiple setups
- We actually know how to work with Ti-6Al-4V titanium, Inconel 718, and 7075 aluminum – complete with the material certs to prove it
- Tolerances hit ±0.003″ (±0.076 mm) or tighter, and every critical dimension gets verified through CMM inspection
- The equipment lineup includes 15 advanced CNC machines with 55″ Z-axis capacity for those bigger aerospace components
What is Aerospace CNC Machining?
Aerospace CNC machining is computer-controlled manufacturing that produces aerospace parts with tolerances between ±0.003″ and ±0.0001″ using multi-axis equipment. CNC (Computer Numerical Control) systems guide cutting tools through programmed toolpaths to remove material from titanium, aluminum, and superalloy blocks. This precision manufacturing process creates turbine blades, structural frames, landing gear components, and wing ribs for commercial aircraft, military jets, and spacecraft applications.
The aerospace industry requires tighter tolerances than automotive or industrial manufacturing because component failures can have catastrophic consequences. A turbine blade with improper dimensions creates imbalance at 20,000 RPM, potentially causing engine failure. AS9100D certification establishes the quality management framework for aerospace machining companies, extending ISO 9001 requirements with aerospace-specific controls for configuration management and complete material traceability. The latest insights show that Asia-Pacific is in control of the CNC machine market share, with over 55% in 2024.
Why is 5-Axis CNC Machining Essential for Aerospace Components?
CNC machining plays a crucial role in aerospace manufacturing because 5-axis capabilities allow cutting tools to approach workpieces from any angle by adding A-axis and B-axis rotation to standard X, Y, Z linear movement. This capability machines complex contoured surfaces like turbine blade airfoils in a single setup, eliminating tolerance stack-up from multiple operations. Aerospace manufacturers specify 5-axis machining for components with compound curves, undercuts, and thin-walled structures that cannot be accessed with 3-axis equipment.
3-Axis vs. 5-Axis Comparison
| Feature | 3-Axis Machining | 5-Axis Simultaneous |
|---|---|---|
| Setup Requirements | 4+ setups for complex parts | Single setup operation |
| Tolerance Achievement | ±0.005″ typical | ±0.003″ or tighter |
| Surface Finish | 63-125 Ra | 16-32 Ra |
| Production Time | Baseline | 40-60% faster |
Traditional 3-axis machining limits tool approach to perpendicular angles relative to the workpiece, requiring multiple setups to access different surfaces. Each setup introduces positioning errors that accumulate, potentially exceeding industry standards. The versatility of CNC machining with simultaneous five-axis movement creates superior surface finishes on sculptured geometries, preventing the gouging and faceting common with 3-axis step-over strategies.
What Aerospace Materials Can We CNC Machine?
We machine Ti-6Al-4V titanium, 7075 and 2024 aluminum alloys, Inconel 718 superalloy, and aerospace composites with complete material traceability documentation. Materials used in aerospace CNC machining require specialized cutting strategies, tooling, and parameters based on thermal conductivity, work hardening characteristics, and abrasiveness. Material selection depends on component requirements including strength-to-weight ratios, temperature resistance, and corrosion protection for aerospace applications.
| Material | Density | Temperature Resistance | Tensile Strength | Applications |
|---|---|---|---|---|
| Ti-6Al-4V Titanium | 4.43 g/cm³ | 1,000 °F (538 °C) | 130,000 psi | Engine components, landing gear |
| 7075 Aluminum | 2.81 g/cm³ | 300 °F (149 °C) | 83,000 psi | Wing structures, fuselage |
| Inconel 718 | 8.19 g/cm³ | 2,200 °F (1,204 °C) | 200,000 psi | Turbine blades, combustion chambers |
| 2024 Aluminum | 2.78 g/cm³ | 250 °F (121 °C) | 64,000 psi | Wing spars, aircraft interiors |
Titanium Alloy Machining
Ti-6Al-4V titanium offers a strength-to-weight ratio superior to steel at half the weight, making it essential for landing gear and engine mounts used in aerospace. This Grade 5 titanium alloy contains 6% aluminum and 4% vanadium, providing corrosion resistance in saltwater environments. We machine Ti-6Al-4V using carbide cutting tools at surface speeds of 50-150 SFM with high-pressure coolant to prevent work hardening.
Titanium’s low thermal conductivity concentrates heat at the cutting edge, accelerating tool wear. Through-spindle coolant systems deliver lubricant directly to the cutting zone at pressures exceeding 1,000 PSI, extending tool life significantly compared to flood coolant methods.
Aluminum Alloy Capabilities
7075 aluminum alloy provides the highest strength among aluminum grades, with T6 temper achieving 83,000 PSI tensile strength while maintaining a density of 2.81 g/cm³. This zinc-based alloy machines at surface speeds of 800-1,200 SFM, allowing rapid material removal for large fuselage components and wing structures in the global aerospace industry.
2024 aluminum alloy offers superior fatigue resistance over 7075, making it preferable for parts for aerospace experiencing cyclic loading, like wing spars and ribs. The copper content (3.8-4.9%) provides better crack propagation resistance, though tensile strength drops to 64,000 PSI in T4 temper.
Inconel Superalloy Processing
Inconel 718 maintains yield strength exceeding 150,000 PSI at 1,200 °F, essential for turbine blades exposed to combustion gas temperatures of 2,200 °F. This nickel-chromium superalloy contains niobium and molybdenum additions that form gamma-prime and gamma-double-prime precipitates, preventing dislocation movement at elevated temperatures crucial in aerospace operations.
CNC machining is employed to process Inconel 718 at conservative surface speeds of 30-60 SFM, with depths of cut limited to 0.040″ (1.02 mm) per pass. The material generates cutting forces 2.5 times greater than steel, demanding machines with 40 HP spindles and rigid construction.
What Tolerances Can Aerospace Precision Machining Achieve?
Precision CNC machining maintains standard tolerances of ±0.003″ (±0.076 mm) for general features, with critical aerospace dimensions achieving ±0.001″ (±0.025 mm) or tighter when specified. CMM (Coordinate Measuring Machine) inspection verifies dimensional accuracy with measurement uncertainty of ±0.0001″ (±0.0025 mm), ensuring aerospace components often meet exact design specifications. Statistical Process Control monitors dimensional trends during production, maintaining Cpk values above 1.33 for critical features as required by AS9100D quality standards.
Temperature Control Requirements
Temperature control proves essential for achieving aerospace tolerances because a 5 °F temperature change causes a 12″ (305 mm) aluminum component to expand 0.0008″ (0.02 mm). We maintain our machining facility at 68 °F ±2 °F (20 °C ±1 °C) with CMM inspection rooms held at 68 °F ±0.5 °F, ensuring that aerospace components receive accurate measurement. Components thermally stabilize for minimum 4 hours before final inspection.
Surface Finish Specifications
Surface finish specifications typically range from 125 Ra microinches for structural components to 16 Ra for aerodynamic surfaces. Our 5-axis finishing strategies employ ball-end mills with 0.002″ (0.051 mm) step-over distances, creating surface textures of 32 Ra or better without secondary grinding operations.
What Types of Aerospace CNC Machined Parts do We Produce?
We manufacture engine components including turbine blades with aerodynamic profiles, engine mounts, and combustion chamber parts requiring Inconel 718 for high-temperature resistance. Structural airframe components include wing ribs with complex contours, fuselage brackets, and reinforcement plates machined from 7075 aluminum. Landing gear components demand high-strength titanium alloys for load-bearing applications handling repeated stress cycles.
Engine System Parts
- Turbine blades with compound curve airfoils
- Engine mount structural supports
- Heat shield brackets for thermal protection
- Fuel system housings and manifolds
Structural Components
- Wing ribs optimized for airflow
- Fuselage brackets and fittings
- Structural frames and supports
- Landing gear actuator housings
Avionics Enclosures
- Sensor housings protecting electronic systems
- Control panel mounting brackets
- Interior cabin structural fittings
- Antenna mount assemblies
How does Our Aerospace Machining Process Work?
Our aerospace machining process begins with DFM (Design for Manufacturability) analysis within 24 hours of receiving CAD files in STEP, IGES, or Parasolid formats. Aerospace engineers review part geometry for potential issues like thin walls below 0.020″ (0.51 mm) thickness, sharp internal corners requiring specialized tooling, and features impossible to access with standard cutting tools.
