Project Overview
An aerospace component supplier required precision manufacturing of lightweight structural parts for aircraft systems. The project demanded AS9100 certification, extreme tolerances, and high-performance materials capable of withstanding aerospace operating conditions.
Challenge
The primary challenges included:
- Aerospace Certification: AS9100D quality system requirements
- Extreme Tolerances: ±0.025mm on critical features
- High-Performance Materials: PEI (Ultem) and PEEK for demanding applications
- Full Traceability: Complete documentation from raw material to finished part
- Environmental Resistance: Must withstand temperature extremes and aviation fluids
Solution
Our engineering team developed a comprehensive solution:
Quality System
- AS9100D certified manufacturing processes
- First Article Inspection (FAI) per AS9102
- Full lot traceability with certificates of conformity
- Comprehensive inspection records
Material Expertise
- PEI (Polyetherimide) for high-temperature applications
- PEEK (Polyetheretherketone) for extreme performance requirements
- Both materials offer excellent chemical resistance and dimensional stability
Precision Manufacturing
- High-precision tooling with hardened steel inserts
- Climate-controlled production environment
- CMM verification on all critical dimensions
- Statistical process control for key characteristics
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Certification | AS9100D | Achieved |
| Dimensional Cpk | �?.67 | 1.82 |
| Weight Reduction | 40% | 50% |
| Field Failures | 0 | 0 |
| On-Time Delivery | 98% | 100% |
Key Success Factors
- Quality Commitment: Investment in AS9100D certification and aerospace-grade processes
- Material Knowledge: Deep expertise in high-performance engineering resins
- Precision Capability: Advanced tooling and inspection for extreme tolerances
- Documentation: Comprehensive traceability meeting aerospace requirements
Customer Testimonial
“CoreLMould’s AS9100D certification and precision capabilities make them a valuable aerospace partner. They’ve delivered 100K+ parts with zero defects and complete documentation. Their understanding of aerospace requirements is impressive.”
- Quality Manager, Aerospace Component Supplier