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Fabrication

The AirCorps fabrication team specializes in the use of traditional and state-of-the-art methods to manufacture and produce aircraft parts. Our adherence to the FAA-PMA Quality System, range of capabilities, and exacting detail are evident in the award-winning restoration work for which AirCorps is known. We have built this reputation by fabricating parts for the legacy and warbird markets, but can also produce approved components for other aircraft and industries. Whether it's stretching a leading edge skin, spot-welding an assembly, machining a main landing gear casting, or producing a formed sheet metal part, customers benefit from working with a premier production team who have access to an extensive collection of resources, equipment and tools.

CONTACT US:

AirCorps Aviation Fabrication Team 
218-444-4478 ext 104 
danm@aircorpsaviation.com

Shop Highlights

  • FAA PMA Quality System
  • Solidworks CAD Design Software
  • BobCAD / CAM Machining Software
  • Full Repertoire of CNC Equipment
  • 3D Scanning & Reverse Engineering
  • 30,000 Sq. ft. machine shop
  • Team of six full time machinists with 100+ years of experience

Internal Process Capabilities

  • FAA-PMA Quality System
  • CNC Machining
  • CNC Turning
  • CNC Routering
  • 3D Scanning
  • Stretch Forming
  • Rubber Form Pressing
  • Routering
  • Aluminum Heat Treat
  • Spot Welding
  • Riveting
  • Sheet Plastic Forming

Managed Outside Processes

  • Formed Laminated Glass
  • Deep Draw
  • Aluminum Castings
  • Aluminum Forgings
  • Magnesium Castings
  • Aluminum Extrusions
  • Rubber Isolation Mounts
  • Springs
  • CAD Plating
  • Anodizing
  • Parkerizing
  • Hard Chroming
Fabrication AirCorps Aviation
Screen Shot 2016-06-28 at 1.32.00 PM
CNC Machine

Inspection

  • Nortec 500S, FM-140, ED-520 - Digital & Analog Flow Detection & Conductivity Testing
  • Zyglo ZL-60D, 2L-67 - Water-Washable Fluorescent Penetrants

Welding

  • Tig Welding - Ferrous & Non-Ferrous - 300 Amp Miller Aerowave
  • Aluminum Spotwelding - Sciaky 90KVA - 3/16 2024-T3 Capacity

Assembly

  • Hot Dimpler / Riveter
  • Cable Swager & Load Testing

CAD / CAM

  • Solidworks
  • BobCad/Cam
  • Creaform VX Model

Metal Forming Equipment

  • Sheet Metal Stretcher Table - 250 Ton - 102" x 70" Capacity
  • CNC Press Brake - 8 foot - 35 Ton
  • Various Sheet Metal Shears
  • Various Box and Pan Brakes
  • Farnham Roller - 12 Foot Capacity
  • 570 Ton Rubber Press (Hydro-forming Sheetmetal Parts) 24" x 34"
  • 80 and 55 Ton Shop Presses
  • Digital Control Heat Treat Oven - 24" x 18" x 43"
  • CecoStamp Drop Hammer - 32" x 32"

Machine Shop Equipment


  • CNC Vertical Mill - XYZ: 30" x 16" x 20"
  • CNC Vertical Mill - XYZ: 40" x 20" x 25"
  • CNC Router - XYZ: 120" x 48 " x 10"

  • Bridgeport Mill - XYZ: 36" x 13" x 20"
  • CNC Chucker Lathe - 6" Diameter - 6" Length
  • Engine Lathe - 15" Diameter - 48" Length

 

SHORTAGE

When parts are required and clients have none available we are able to utilize our experience, capabilities, and range of internal and external managed services to quickly respond to their needs.

 

SHORTAGE

 

QUOTING

Our team can quickly provide a quote and timeline for production of parts drawing on our years of parts fabrication experience. Our vast library of technical data housed on AirCorps Library (link) makes information gathering efficient.

QUOTE

 

PROCESSING

CAD / CAM specialists are able to quickly turn around drawings for approval. When necessary our state of the art 3D scanning and reverse engineering group can provide accurate dimensional analysis for parts which have no technical drawings.

PROCESSING

 

PRODUCTION

By internally quoting, acquiring, and managing the processing of manufactured parts everyday we can deliver customers precise high quality parts quickly and efficiently.

REPRODUCTION

BENEFITS OF AIRCORPS FABRICATION

Expertise: experienced team producing parts under an approved FAA-PMA quality control system. Our diversity of clients and world class restorations have guided our comprehensive understanding parts fabrication..


Capabilities: the range of capabilities we manage both internal and external defines who we are. We are staffed and equipped with the experience and equipment necessary to produce finished and ready for install components. 


Quality Control: We are proud to manage a FAA-PMA Quality Control System and will continue to develop our quality management systems to further expand our opportunities and offerings.


Customer Service: client relationships are rooted in our knowledge of being both an world class restorer of aircraft, consumer, and by supporting outside customers. Our interactions are relationship driven, long-term, and valued.


Portfolio of Resources: our growing library of original manufacturer blueprints, manuals, and resources allows us to quickly access rare technical data important to understanding, reproducing, and delivering exacting components.


Honoring Techniques & Methods: our team understands and embraces manufacturing techniques of vendors not in business today. We strive to reproduce that historic look while balancing the cost and efficiency afforded by modern technologies.


Consistency: having fabricated thousands of parts, we know what works and what doesn't. We deliver parts organized and labeled professionally that integrate seamlessly into a shop setting.


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