Capability: Turnkey Program Manufacturing Services
With our vertically integrated manufacturing capabilities, Primus Aerospace offers turnkey program manufacturing of high-precision, high-complexity machined products for the aerospace, defense, and deep space industries. We manage the entire manufacturing program, from engineering and design to tooling, multi-axis precision machining, assembly, and specialty processes. Our services incorporate robust, end-to-end quality assurance and we administer program-specific inventory systems that align with custom workflows and stock control policies.
As a technology-oriented company, we engineer solutions that integrate intelligent product design with sophisticated manufacturing processes. We operate a state-of-the-art production facility housing high-value machining centers capable of reliable and repeatable production of critical parts. With equipment assets that include 7-axis mills and 9-axis turning centers, our capabilities include complex milling and turning as well as thin-walled machining down to .010” wall thickness. Along with microtube machining and microtube bending, we also perform hard turning and milling up to 70 Rockwell C. We work with all primary aerospace alloys, such as aluminum, titanium, Hastelloy®, and Inconel®, and we also machine parts from advanced engineering composites. We uphold dimensional tolerances and repeatability up to ±0.0001” with measurement accuracy to .00001” on parts as large as 20.0” in diameter and 84.0” in length.
Our services platform incorporates all aspects of mechanical and electrical assembly as well as value-added processes such as EDM, lapping, grinding, welding, and heat treating. We handle any surface finish and deburring requirements. Inside our climate-controlled Quality Assurance Laboratory, trained quality inspectors leverage a full array of test and measurement equipment to verify products comply with specifications. Accredited to both ISO 9001:2008 and AS 9100 Rev C, our quality management program supports FEMA, PPAP, and customer-specific risk analysis, and we maintain robust traceability documentation for raw materials, machining processes, outside processes, assembly, and all other critical services.
With our program management expertise, value engineering, and robust manufacturing systems, we help companies reduce lead-time and improve product quality while reducing costs and simplifying supply chain management. Contact us directly for a consultation.
|General Capabilities||Engineering and Design:
Assembly And Specialty Processes:
· Gear Cutting
Inventory Stocking Arrangements:
· Vendor Managed Inventory
· Safety Stock
Dimensional Tolerances and Repeatability To 0.0001”. Measurement Of Tolerances Up to 10 Millionths.
Milling Size Capability Up to 84” Lg.
Turning Size Capability Up to 20” Dia.
|Manufacturing Process||5-Axis Aerospace Machining
Casting & Forging Machining
Exotic Material Machining
Hard Turning and Milling
Additive manufacturing (3D printing)
· Contour Turning
· Form Turning
· Taper Turning
· Straight Turning
|.060” to 23” in Rotation|
|.060” to 84.0” in Length|
|.060” to 22.0” in Diameter|
|Thin-Walled Machining||.010” Wall Thickness Achieved on Cylindrical Housings, Deep Pocket Milling and Micro-Tubing|
|Hard Turning and Milling
|Up To 70 Rockwell C|
|Milling Axis||3 axis
|Turning Axis||2 axis
|Dimensional Tolerances and Repeatability
|Measurement Of Tolerances
|Up to 10 Millionths|
|Mechanical Assembly Capabilities||Staking
NAS / MS Hardware
|Electrical Assembly Capabilities||Soldering
Cables / Harnesses
Conductivity / Continuity Testing
|Examples Of Manufactured Products||Castings & Forgings – Machining of Aluminum, Steel And Titanium
Safing & Arming Systems
Passenger / Crew Seating
Long Glass Fiber Reinforced (LGFR) Plastic
|Lead Times||Quoted On Job-by-Job Basis
Emergency Services Available
Rush Services Available
|Efficiency||Six Sigma Certification
|Certifications||AS 9100 D
Aerospace Industry Standard
International Organization For Standardization
National Aerospace And Defense Contractors Accreditation Program
What is honing?
Honing is mechanical finishing process used by aerospace machine shops and outside processors to achieve a precision surface on a metal part. Hones use superabrasives, also known as a honing stone, to a specific finish over the entirety of a metal surface. These abrasive stones are configured on a tool assembly to provide consistent abrasion to the work piece.. Honing is also called bore finishing, as it’s most commonly conducted on cylindrical surfaces as a finishing technique.
Honing is conducted with honing stones or with wire brushes that provide a very specific level of abrasion to the metal work piece. Honing stones are generally an aluminum oxide or silicon carbide abrasive material, which is bonded with resin.
Where did honing originate?
Modern honing techniques date back to the 1940’s with the foundation of Superior Hone in Elkhart, IN. The original intend of mechanical honing equipment was to deglaze automotive cylinder bores, but as the technique was perfected, additional applications presented themselves.
What are common types of mechanical honing equipment?
- Vertical hone – Vertical honing machines use a drive shaft that is oriented vertically and moves along the work piece in an up and down motion. An example of a vertical hone would be the Ohio Tool Works PowerHone. Primus Aerospace utilizes an onsite Barnes 3010 honer to provide in-house honing as part of a turn-key manufacturing solution.
- Horizontal hone – Horizontal honing machines are laid out across a floor footprint where the drive shaft moves forward and backward through a work piece. An example of a horizontal hone would be the Ohio Tool Works VersaHone. Sunnen is another manufacturer that specializes in honing equipment for vehicle engine applications.
Honing machines also differ in their capability to handle various bore diameters and part lengths / heights. Primus’s honing capability specialize in parts that are ideally used for aerospace hydraulic reservoirs and cylinders.
What is single pass vs multi pass honing?
Most honing applications take multiple passes (known as stroke honing) to achieve the desired surface finish and depth. Specific applications, such as engine crank arms or cam bores, require single pass honing to ideal performance.
Why is honing performed in aerospace and defense applications?
Honing allows a manufacturer to achieve a precision surface finish that is critical for some aerospace applications, such as hydraulic systems. Aircraft manufacturers and tier one suppliers design hydraulic systems as part of the control system. In addition to aerospace control systems, honed aerospace parts are found in pumps, valve sleeves, accumulators, fuse pins, and landing gear components. Parts are honed to reduce friction, remove burrs, and increase equipment dependability over it’s service life. In specific aerospace applications, the inner bores of gears or weapon barrels are honed.
What is the advantage of a machine shop that has integrated honing?
While many aerospace and defense machine shops offer honing as part of their production sequence, very few have the honing capability inside their company. When aerospace machine shops produce a part, the production sequence may require additional capabilities (such as honing, painting, precision grinding) to meet the customer’s build-to-print requirements. When those capabilities are not organic to the part manufacturer, they will utilize outside processors (also known as OP Houses) to perform the specialized work. More sophisticated machine shops have additional value added services inside the company, which allows them to expedite priority parts and ensures adherence to a single quality management system (QMS), generally at the AS9100 level. Primus Aerospace is constantly adding additional capabilities, such as wire EDM, honing, and grinding, to it’s ability to provide turn-key manufacturing solutions for aerospace and defense parts.
Does Primus offer honing to aerospace & defense customers?
Yes! Primus Aerospace offers honing as a valued added service to it’s build-to-print aerospace part production service. Primus does not offer today, stand alone honing as a separate service to other local machine shops, but could in the future.