Sheet Metal & Fabrication for the Aerospace Industry

Sheet metal is a smart way to achieve strength, stiffness and low weight with repeatable cost. Cold forming preserves material properties and keeps distortion in check, which is especially important for stainless, titanium and thicker sections. By profiling near-net blanks in-house, we control the flat pattern, grain direction and hole positions before forming, so the part flows cleanly into machining, welding and final assembly.

We focus on formed brackets and carriers, frames and ribs, access panels and covers, and light to medium gauge enclosures and chassis. Parts start as waterjet blanks where that suits the design, then move into forming with tooling and fixtures set to your drawing. If a feature calls for tight tolerances, we take the part into CNC machining before or after forming. Hardware such as captive nuts and studs is fitted to specification, and assemblies are built, checked and packed ready for your line.

Sheet metal at GASE is part of a joined-up path. A typical job runs waterjet blank, forming, CNC machining for tight faces or hole patterns, then welding, finishing and final assembly. Everything sits on one campus, with one job pack and one schedule, which removes supplier hand-offs and gives you faster response when plans change.

Send DXF or DWG for flat patterns, or STEP, IGES, Parasolid or native SOLIDWORKS if you prefer us to create the flat. We consider bend radii, grain direction, K-factors and hole to bend distances when we generate the route. Our team nests parts for yield and flow, which helps on high-value alloys and mixed kits. If you already have a preferred bend table, include it and we will follow it.

Work runs under our aerospace-grade quality management system. Inspection is scaled to the job and can include first-off, in-process and final checks, with CMM used where required. We supply the documentation you need, from standard inspection reports and certificates of conformity through to AS9102-style FAIRs and fully traceable data packs.

Can you work from our flat patterns or do you create them
Either. Send DXF or DWG if you have them, or share the 3D model and we will generate the flat pattern and confirm bend allowances before we start.

What materials and gauges do you support
Aluminium and its alloys, stainless and other steels, titanium and copper alloys are routine. Gauge and thickness depend on geometry and bend radii, we will advise the most stable route once we review your model.

How do you keep holes and slots accurate after forming
We plan hole positions against bend lines, use verified bend data and, where needed, machine critical features after forming to lock in position and size.

Can you install hardware and build sub-assemblies
Yes. We fit captive nuts, studs and other inserts, and we assemble and kit parts to your build plan so they land ready for installation.

Do you handle finishing and coatings
Yes. We manage finishing and treatments through approved partners and handle the paperwork and inspection so you have one supplier to deal with.

How do we start and what files do you accept
Send STEP, IGES, Parasolid or SOLIDWORKS, or DXF and drawings for flats. Tell us the material, finish and volumes, we will review manufacturability, confirm the route and come back with a lead time.

Upload your drawing or model and we will review the flat pattern, nesting and forming approach, then advise on any features that should be machined or welded after form. If you would like to see the route in person, we can arrange a visit to the Crayford site.