Manufacturing & Assembly for the Aerospace Industry

Turnkey manufacturing at GASE starts with the range of disciplines we have in house. Across our four sites we run 5 axis and 3 axis CNC milling, multi axis turning, precision fine limit sheet metal work, 5 axis waterjet cutting, CAA approved welding, specialist non metallic machining and a full suite of finishing processes.

Instead of placing separate orders with different suppliers for each operation, you can place a single package of work with us. We plan and manage the full route, from cutting and forming through to machining, welding, finishing and final build. That gives better control over quality, fewer handoffs and shorter overall lead times.

Key in house disciplines include

• CNC milling and 5 axis machining (+GF+ Mikron partnership)
• Multi axis turning using Mori Seiki lathes
• Precision fine limit sheet metal work and presswork
• OMAX waterjet cutting for metallic and non metallic materials
• CAA approved welding and welded fabrications
• Finishing, cleaning and cosmetic preparation
• Mechanical assembly of machined and fabricated components

Because all of this sits within one organisation, it is easier to maintain consistency from the first operation to the last.

Turnkey work is supported by our engineering and project management team, who stay with the job from early design input through to series production. We can pick up new projects at different stages, from an initial concept sketch to a fully detailed drawing and model set.

In the early stages we can help you review designs from a manufacturing point of view, suggesting changes that make parts easier to machine, form and assemble. Our CAD/CAM and programming capability allows us to work directly from your 3D models and 2D drawings, generating tool paths and cutting data for milling, turning, sheet metal and waterjet.

As the project develops, we manage prototypes, pre production builds and then regular batch work, keeping the same core team in place. For programmes that need formal approvals, we can build in first article inspection to AS9102, controlled through our Q-Pulse inspection management system.

The result is a controlled, traceable route into production rather than a collection of disconnected subcontracts.

What makes our turnkey offer practical is the way the factories are organised.

• Factory Site 1 is the centre of excellence for fine limit sheet metal work, CAA approved welded components, waterjet cutting and 5 axis milling.
• Factory Site 2 is the 5 axis machining centre of excellence, based around +GF+ Mikron milling machines.
• Factory Site 3 is the turning centre of excellence, focused on Mori Seiki multi axis lathes.
• Factory Site 4 is dedicated to specialist non metallic machining.

This structure allows us to build manufacturing routes that make sense, without losing control of parts between operations. A typical assembly might start with waterjet cut blanks, move through sheet metal punching and forming, then into 5 axis machining for detailed features, on to welding and finally into finishing and assembly.

Because we manage all stages internally, we can tweak sequences, balance workloads and resolve any issues quickly without waiting on third parties.

The brochure shows several examples of how we bring disciplines together into finished products. aircraft parts machined and fabricated from titanium, pressurised water boilers for aircraft, nuclear plant fire traps and assembled machined and fabricated components for aircraft are all produced in house using a mix of machining, sheet metal, welding and assembly.

These examples give a good feel for the type of work suited to our turnkey service

• Complex aerospace components that require machining, fabrication and welding on the same part
• Pressurised tanks and boilers where forming, machining, welding and test all need to be controlled
• Safety related structures for nuclear and power applications, such as fire traps and barriers
• Electronic and communication enclosures that combine fine limit sheet metal skins with machined frames and detailed brackets

We are comfortable with both structural and cosmetic requirements. Fine limit sheet metal heritage means we pay attention to appearance as well as fit, which is important for visible cabin components and customer facing equipment.

Turnkey manufacturing is not just about metal cutting and welding. The finishing stages are just as important if assemblies are going straight to line fit or installation.

In house we offer straight graining and thicknessing, bead blasting, vibratory rumbling and two stage ultrasonic cleaning, using equipment such as Time Savers thicknessing machines, Guyson Euroblast cabinets, Walther Trowal vibratory units and Guyson ultrasonic cleaning systems.

We also manage subcontract finishes, including painting, powder coating and plating, to your specifications. This is handled as part of the same project management and quality framework, so external treatments are controlled and documented in the same way as internal processes.

By the time assemblies leave GASE, they have been fully machined, fabricated, welded, finished, cleaned and assembled, ready either for your own final test or for direct installation into aircraft, nuclear plant, electronic systems or other equipment as required.

Turnkey projects at GASE are covered by our AS9100 Rev D quality management system, certified by Bureau Veritas. Inspection is supported by Q-Pulse AS9102 inspection management and a CRYSTA Apex CNC CMM with scanning capability, allowing us to inspect to GD&T with profile scanning where required.

For full assemblies we can provide traceability back through all key processes, including

• Material certification
• Process and operation records for machining, sheet metal, waterjet and welding
• Welder and procedure identification for critical welds
• CMM and other dimensional inspection reports
• Cleanliness and FOD related checks where specified

This level of control is particularly important for aerospace, nuclear and high end electronics projects, where it is not enough for the part to be right, the route and the records must be right as well.

To support turnkey work we operate our own fleet of vehicles for deliveries and collections, which gives us extra flexibility when handling urgent projects or sensitive assemblies.

Because the full build is completed on one campus, there are no intermediate shipments between suppliers. Parts and assemblies only leave site when they are ready for you, which reduces the risk of damage in transit and cuts down on admin and handling time.

Working with GASE Engineering for full turnkey manufacturing and assembly gives you a single, accountable partner from raw material to finished assembly. You gain access to a mix of disciplines that few subcontractors can match on one site, backed by over six decades of experience and an aerospace grade quality system.

In practical terms you benefit from

• One supplier managing machining, sheet metal, waterjet, welding, finishing and assembly
• Project management from concept and CAD through to production and line fit
• A four factory campus in Crayford with dedicated centres of excellence
• Proven experience in complex aerospace, nuclear and electronics projects
• Stable capacity for prototypes, complex assemblies and high volume batch work

If you would like to discuss a new assembly project, review an existing multi supplier route or arrange a visit to see how our turnkey manufacturing and assembly operates in practice, the GASE Engineering team will be happy to help.