1-218-444-4478 PO BOX 847, BEMIDJI, MN 56619
1-218-444-4478 PO BOX 847, BEMIDJI, MN 56619

Legacy Aircraft Replacement Part Fabrication

We Engineer/Build/Create the Parts You Need

Our Capabilities

Reverse Engineering

CAD / CAM

Metal Forming

CNC Machining

Assembly & Inspection

Fixtures & Jigs

Quick Turn Around

Our team works diligently to ensure timely completion so you receive your part as soon as possible.

No Project Too Big or Small

Our experienced staff and state-of-the-art equipment can handle almost any job you could imagine.

FAA/PMA

We adhere to all FAA/PMA standards and produce parts of exceptional quality.

Available Fabrication Processes

Stretch Forming

Hydro Pressing

Drop Hammered

Machined Parts

Castings & Forgings

Assemblies

3D Scanning

Tooling

Case Studies

PROBLEM

AOG (Aircraft On Ground) forced the necessity for an immediate part.  The client needed a complex formed sheet metal part ASAP.

SOLUTION

AirCorps Fabrication was able to fabricate tooling and the replacement part within several days.

PROBLEM

A regional air cargo carrier wanted a more affordable and faster repair solution for a cracking engine cowl.

SOLUTION

Utilizing 3D scanning to capture highly accurate dimensions.  A doubler was engineered in CAD and fabricated by spin forming.

PROBLEM

An aircraft repair company needed a source that could reverse engineer and fabricate short runs of obsolete damaged ribs.

SOLUTION

AirCorps Fabrication is capable of taking an original part without drawings and reproduce perfectly fitting replacements.

PROBLEM

Tasked with restoring an aircraft and with very little parts and only original hand drawings, the project required 3D drawing formats to utilize modern manufacturing equipment.

SOLUTION

With AirCorps aviation experienced CAD technicians, AirCorps has converted thousands of 2D drawings into 3D CAD models that can easily translate to modern machining file formats.

PROBLEM

A client that engineers modifications to aircraft needed a supplier that could fabricate and deliver finished assemblies.

SOLUTION

Beyond simply fabricating an individual part, AirCorps Fabrication can provide a fully finished, multi-part assembly.

Frequently Asked Questions

Do you only fabricate parts for WWII aircraft?

No, we fabricate and manufacture parts for a large variety of legacy to modern aircraft types.

I have a “certified aircraft” but can not obtain original drawings for a replacement part. Can you help me?

Yes, we can reverse engineer and provide assistance working with the FAA and DER’s to obtain the necessary approved data to fabricate most parts.

How long does it take to get a part reverse engineered and fabricated?

Due to the varying complexity of every part it is something that is quantified in the quoting process.

I have the resources capable to fabricate the part, however, I need reverse engineering services.

We cater to our customers needs and can provide individual services upon request.

Can you manufacture PMA parts that are OEM proprietary?

Yes! We do not use Identicality to obtain PMA on OEM proprietary parts. We use another FAA approved method, referred to as Test & Analysis or Test & Computations; which is sometimes referred to as reverse engineering. The part undergoes studies to understand the part function, application and criticality. In addition we capture all necessary dimensions, features and material characteristics of the OEM part from which we will create our own engineering/ production drawing to manufacture the PMA replacement part.

Shop Highlights

  • Specialization in formed aluminum structural components
  • FAA PMA Quality System
  • Full repertoire of CNC equipment
  • 3D Scanning to CAD model creation
  • Full service engineering to fabrication part delivery
  • 3,000 sq. ft. machine shop
  • Specialize in low volume orders

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 work for which AirCorps is known.

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.

Current Customers

Shop Equipment Details

Metal Forming Equipment

SHEET METAL STRETCHER TABLE
300 Ton – 102” x 70”, Stretch forming

1500 TON PRESS
30” x 72” x 6” Rubber Box, Hydroform

460 TON PRESS
24” x 34” x 4” Rubber Box, Hydroform

80 TON PRESS
60” x 12” Table – 48” Slide, Shop Press

55 TON PRESS
36” x 9” Table – 24” Slide, Shop Press

DROP HAMMER
32” x 32” Table, Chambersburg Cecostamp

CNC PRESS BRAKE
35 Ton – 6ft , Acrotech DI-Arco

SHEET METAL SHEARS
48” x 12 Gauge

BOX AND PAN BRAKES

FARNHAM ROLLER
12ft Capacity, Farnham

DIGITAL CONTROL HEAT TREAT OVEN
60” x 60” x 60”, Certified per AMS 2770, Standard, Park Thermal

DIGITAL CONTROL HEAT TREAT OVEN
42” x 24” x 18”, Certified per AMS 2770, Standard, Thermcraft

 

CAD / CAM Design Software

CAD SOFTWARE
Solid-body CAD Modeling (editable model)
Solidworks 2019

CAM SOFTWARE
Solid-body CAD Modeling (Machine programming)
CAMWorks 2019

Machine Shop Equipment

5 AXIS CNC VERTICAL MILL
XYZ: 30” x 20” x 20”, Haas UMC 750

3 AXIS CNC VERTICAL MILL
XYZ: 30” x 16” x 20”, Haas Super VF-2

3 AXIS CNC VERTICAL MILL
XYZ: 30” x 20” x 20”, Haas VM-2

3 AXIS CNC VERTICAL MILL
XYZ: 40” x 20” x 25”, Haas VF-3

3 AXIS CNC VERTICAL MILL
XYZ: 40” x 26” x 25”, Haas VM-3

3 AXIS CNC LATHE
10” Diameter x 20” Length, Haas SL-20, C axis, Live Tooling

3 AXIS CNC ROUTER
XYZ: 120” x 48” x 10”, Routech Record 220

3 AXIS CNC ROUTER
XYZ: 96” x 48” x 7”, DMS Patriot 4’ x 8’

3 AXIS CNC ROUTER
XYZ: 120” x 60” x 15”, DMS Patriot 5’ x 10’ Plus

VERTICAL MILL
XYZ: 36” x 13” x 20”, Bridgeport

CNC CHUCKER LATHE
6” Diameter x 6” Length, CMS

ENGINE LATHE
15” Diameter x 48” Length, Clausing Colchester 15

Welding

ALUMINUM SPOT WELDING
3/16” 2024-T3 Capacity, Sciaky 90KVA Mil-spec

TIG WELDING
Ferrous & Non-Ferrous AWS D17.1, Miller Aerowave 300 Amp

Inspection

COORDINATE MEASURING MACHINE
XYZ: 20” x 23” x 20”, Hexagon TIGO SF
Hexagon PC-DMIS 2017 software

HAND-HELD 3D SCANNER
Portable 3D laser scanning, (Mesh surface output)
Creaform VXModel software, Creaform Handyscan 700

OPTICAL COMPARATOR
14” Horizontal, American Optical Co.

PROFILOMETER
Surface finish check too

Other / Unique Equipment

IN-HOUSE PAINT BOOTH

INTEGRATED MACHINE TOOL CRIB ORDERING & INVENTORY

FAA REPAIR STATION

ART SERVICES
Custom made placards, decals and name plates

SHEET METAL RACK

Facilities Sq. Ft.

Fabrication shop space: 10,000 sq. ft.