CNC Machining for the Aerospace Industry

Complex geometry, light weight and tight tolerance are normal in aerospace and defence work. Our approach focuses on one-hit strategies for accuracy, fixturing that controls variation, and stable cutting conditions across shifts. The result is parts that measure right first time, with less handling and lower risk of tolerance stack-up. Where a design benefits from a near-net blank, we pair machining with in-house waterjet so parts enter the machine close to finished size, saving time and material.

For complex prismatic work we use multi-pallet 5-axis machining to reduce set-ups and maintain accuracy on families of parts. Pallet queues and standardised fixtures compress changeovers and support extended unattended running. For plate work and simpler forms, our 3/4-axis platforms provide cost-effective throughput using the same verified process controls. Typical outputs include structural brackets, housings, covers and heat-dissipating features across aluminium, steels, titanium, nickel alloys, copper alloys and engineering plastics.

Our Mori Seiki NLX lathes combine turning and milling in a single cycle with driven tooling in X/Y/Z. Hydrafeed bar systems support volume parts where consistent output matters, while the platform’s rigidity and control make it equally suited to development batches. From shafts, spacers and flanges to manifolds and connectors, we machine tight-tolerance turned features with milled details in-cycle, reducing secondary ops and keeping unit costs predictable.

Aerospace
Lightweight brackets, ribs, housings and covers in aluminium, stainless and titanium. One-hit 5-axis strategies minimise tolerance stack-up, while palletisation controls finish and dimensional repeatability across batches.

Defence
Ruggedised enclosures, carriers and interface hardware in stainless and high-strength alloys. Mill-turn consolidates operations, improves positional accuracy and reduces handling on complex outlines.

Nuclear
Thick-section components and assemblies where traceability and documentation are essential. Near-net blanks from waterjet flow straight into machining for tight features and critical interfaces.

Electronics & communications
Avionics and RF enclosures, heat-sinks and chassis parts in aluminium and copper alloys. Controlled kerf from waterjet plus precision machining ensures clean hole patterns and slot features.

Marine
Corrosion-resistant brackets, shafts and frames. We manage material movement during machining and finishing to keep parts true for service conditions.

If your application isn’t listed, send the model and we’ll confirm the most efficient route through waterjet, machining, turning and finishing.

CNC machining at GASE sits inside a joined-up path on one campus. A part can start as a waterjet blank, move to fine-limit sheet metal for forms, then into 5-axis machining for tight features, before welding, finishing and assembly. One schedule, one job pack, consistent controls — fewer hand-offs and faster response to change.

Our in-house team supports NPI from concept to manufacture. We review drawings for manufacturability, programme offline, simulate toolpaths and design fixtures that align with inspection requirements. The toolset includes MAPPS/CAPPS, EDGECAM Five-Axis, ALPHACAM Advanced and SOLIDWORKS Professional, giving a clean hand-off from model to machine and the confidence to run unattended when appropriate.

Jobs run under a documented quality system with inspection embedded at first-off, in-process and final stages. We use calibrated equipment including CMM where required and supply the documentation you need — standard inspection reports and certificates of conformity through to AS9102-style FAIRs and fully traceable data packs.

What sizes can you machine
Up to 800 × 800 × 550 mm on 5-axis, 1200 × 600 × 600 mm on 3-axis, and Ø350 × 1200 mm on mill-turn. If your part sits close to the limits, share the model and we’ll confirm set-up options.

Which materials do you support
Aluminium and its alloys, stainless and tool steels, titanium, nickel alloys, copper alloys and engineering plastics. We’ll advise on the most efficient route by material and geometry.

How do you control accuracy on complex parts
We favour one-hit strategies, rigid fixturing and verified toolpaths. Inspection is built in at first-off and in-process, with CMM used where appropriate.

Do you handle both prototypes and production
Yes. The same controlled methodology runs through quick-turn development parts and scheduled batch production. Palletised automation helps us switch between families without long changeovers.

Can you manage the full route from blank to finished assembly
Yes. We can waterjet, form, machine, turn, weld, finish and assemble on the same campus with a single job pack and traceability.

What files do you accept and how do we start
STEP, IGES, Parasolid and native SOLIDWORKS for 3D, plus drawings. Upload your file with notes on material, finish and volumes — we’ll review DFM, confirm envelopes and come back with a route and lead time.

Upload your drawing or model and we’ll review manufacturability, lead time and any features that should be cut at waterjet before machining. If you’d like to see the cell, we can arrange a visit to the Crayford site.