Mastering Complex Aircraft Assemblies Requires a Broad Range of Capabilities

Addressing Complex Aircraft Assemblies From Every Angle

A variety of capabilities are needed to produce complex aircraft assemblies that meet the demands of the industry, where performance, exacting tolerances, and governing regulations are required. Below we detail some of the many ways Re:Build Cutting Dynamics is able to tackle these challenges.

Hydroforming Lightweight Metal Components

Hydroforming is a specialized manufacturing process that shapes lightweight metal components efficiently. Hydroforming molds metal into complex shapes that are both strong and lightweight — an essential requirement in aerospace manufacturing, where every gram counts. By utilizing hydroforming, we can produce components that significantly reduce the overall weight of an aircraft without compromising structural integrity.

Our expertise in hydroforming allows us to deliver components that meet the stringent standards of the aerospace industry, all while using a process that creates complex shapes with a single tool, in a single setup, with excellent structural integrity. We ensure that each piece is crafted with precision, contributing to the overall efficiency and performance of the aircraft. Whether it’s for airframes, engine components, or other critical structures, our hydroformed parts are designed to exceed expectations.

Thermoplastic Composite Manufacturing

Thermoplastic composites are rapidly becoming the material of choice in aerospace applications, thanks to their lightweight and high-strength properties. These advanced materials offer significant advantages over traditional metals, including improved fuel efficiency, reduced emissions, and enhanced performance. By reducing the weight of the aircraft, thermoplastic composites help airlines achieve better fuel economy and lower operating costs.

Our capabilities in thermoplastic composite manufacturing position us at the forefront of this technological shift. We specialize in creating components that not only meet the rigorous demands of the aerospace industry but also push the boundaries of what is possible with modern materials. Our experience with thermoplastic composites ensures our complex aircraft assemblies meet the standards for durability, reliability, and performance.

Assembly and Kitting

The process of assembling multiple components into a cohesive unit is a complex and meticulous task. Precision and coordination are paramount to ensure that every part fits perfectly and functions as intended. Our assembly and kitting services are designed to simplify this process for our clients, offering end-to-end solutions that streamline the manufacturing process and reduce the potential for errors.

Our kitting services ensure that all necessary parts are organized and ready for assembly, minimizing downtime and maximizing efficiency — including providing directions to where every sub-kit box and bag is located. We can design and produce kits ranging from those supporting high-volume production to kits that support highly complex applications such as retrofitting, MRO, provisioning, and forward stocking complete to your specifications. We use color-coded packaging processes, zone/installation packaging, and lot traceability to ensure full quality compliance and follow your production flow or maintenance event. 

Hot Forming Titanium

Titanium remains one of the most sought-after materials in aerospace manufacturing due to its exceptional strength-to-weight ratio and high-temperature tolerance. However, shaping titanium into precise components requires specialized expertise and equipment. Hot forming is the process that allows us to mold titanium into complex shapes while maintaining its integrity and performance characteristics.

Our expertise in hot form titanium ensures that we can deliver components that are both durable and precisely manufactured. Whether it’s for structural parts, engine components, or other critical applications, our hot-formed titanium parts are designed to withstand the extreme conditions of aerospace environments. We take pride in our ability to produce high-quality titanium components that meet the most demanding specifications.

A Cut Above: Explore how the precision afforded by CNC machining is critical to the aerospace industry. Read more here. 

For Complex Aircraft Assemblies, and More, Turn to Re:Build Cutting Dynamics

As the aerospace industry continues to evolve, the demand for complex aircraft assemblies will only increase. Our comprehensive capabilities in hydroforming lightweight metal components, thermoplastic composite manufacturing, assembly and kitting, hot forming titanium, and more make us the preferred provider for these critical services. We are committed to delivering cutting-edge solutions that meet the challenges of next-generation aircraft design — and ensure our results with strict quality standards backed by certifications critical in the aerospace industry. 

Ready to work with an aerospace parts manufacturer that meets the exacting demands that come with complex aircraft assemblies? Connect with us today to get started.