CAPABILITIES Sheet Metal



Overview

PCC Aerostructures includes four sites with sheet metal capabilities, accounting for nearly 600,000 square feet of manufacturing space. Our product lines range from simple to highly complex formed parts and assemblies, including sheet metal fabrications and welded components, for airframe and engine OEMs.

Sheet Metal Sites and Capabilities include:

Compass Aerospace Northwest  

  • Brake Forming up to 120 inches (3,048 mm)
  • Hydroform up to 150 inches (3,810 mm)
  • Punch Press up to 72 inches (1,828 mm)
  • Stretch Form Profiles up to 300 inches (7,620 mm)

Klune Industries - North Hollywood

  • Brake Forming up to 120 inches (3,048 mm)
  • Bulge Forming up to 220 inches (5,588 mm)
  • Draw Form up to 72 inches (1,828 mm)
  • Hydroform up to 150 inches (3,810 mm)
  • Laser Routing up to 144 inches (3,657 mm)
  • Punch Press up to 72 inches (1,828 mm)
  • Roll Form up to 60 inches (7,620 mm)
  • Stretchform Profiles up to 300 inches (7,620 mm)
  • Stretchform Skins

SPS Aerostructures - Annesley

  • Brake Forming up to 120 inches (3,048 mm)
  • Draw Form up to 72 inches (1,828 mm)
  • Hydroform up to 150 inches (3,810 mm)
  • Laser Routing up to 144 inches (3,657 mm)
  • Punch Press up to 72 inches (1,828 mm)
  • Roll Form
  • Welding & Resistance Welding
  • Brazing & Soldering

SPS Aerostructures - Kunshan

  • Brake Forming up to 120 inches (3,048 mm)
  • Laser Routing up to 144 inches (3,657 mm)
  • Punch Press up to 72 inches (1,828 mm)

Brake Forming

Brake forming is a low cost method of producing low volume – hi mix parts that require tight bends or specific radii typically found on small clips or brackets.

Technology & Equipment

We have brake forming machines ranging from 8' to 12' long. Our seasoned operators produce thousands of different parts each year. Most of the parts produced by the brake form area are details used in the kitting or assembly area. Value proposition

The brake forming process supports PCC Aerostructures' one-stop-shop and reduces the length of the supply chain. We have a large inventory of common tooling which virtually eliminates the need for the customer to pay for tooling on brake formed part


Stretch Forming

PCC Aerostructures uses stretch forming to produce precisely contoured products from both sheet metal and extrusions that meet our customers' challenging expectations.

This process is particularly suited to multi-contoured skins and panels where other forming methods will not achieve proper results. We can stretch a variety of parts ranging from small details to large skins from full sheets of material.


Bulge Forming

With Bulge Forming, PCC Aerostructures can produce large skins and fairings to tight tolerances  with minimal material thinning.

We have developed and manufactured our own bulge forming  equipment specifically designed to produce a range of unique components. This  dedicated process means consistency and repeatability to our customers that  other forming methods would not provide.

The hydro-static bulge forming process adds to PCC Aerostructures' wide range of  forming capabilities and is currently used to produce lip skins and fairings for  a variety of large commercial aircraft. Dedicated tooling saves our customer  machine set-up time and this process is particularly adapted for long production  runs with monthly shipments


Draw Forming

PCC Aerostructures uses draw forming  to produce deep shapes to precise customer specifications including nacelle nose lips, bulkheads, frames and structural skins.

We have a variety of draw form presses ranging from 100 Tons to  1,500 Tons. This capacity allows us to draw multiple size parts. A variety of materials can be formed, such as aluminum, stainless steel, inconel and  titanium. Our dies are designed and manufactured in house, which gives us control of the entire process.

This process is well suited to cup and pan shaped parts, with deep sides that  are difficult to achieve by other forming methods. We have the flexibility to  process both small and large runs while remaining competitive in cost.