Manufacture

CNC Milling

3-axis CNC machine are used for first stage machining operations.
These are robust, high powered machines that allow for rapid material removal.
4- and 5-axis machines with advanced functions are used for high speed, high accuracy final machining.
On-machine inspection can be carried out using touch-probes.
The machines allow for a high degree of process control.
Alos, a high degree of automation is possible for unattended operation (eg. automatic toolchanging and measurement).

Spark erosion (die sink).
Used to produce tunnels for pressure plotting in model wings, which has the dual benefit of reducing the number of coverplates in the airswept surfaces and increasing model strength. Produces features which would be impossible with conventional machining processes (eg. undercuts, non-geometric shapes, fragile features, etc).
Plunge slots in strain gauge balances to produce flexure cages.
EDM drilling permits machining of holes as small as 0.2mm diameter using the EDM process which would otherwise be very difficult to produce.

Wire erosion
Manufacture one piece missile models.
Manufacture of small control surface balances
Non contact process, therefore suitable for fragile parts.

High degree of finesse required for small scale models (accuracy of ±0.025 mm).
Model assembly in preparation for wind tunnel testing.
Final polishing of airswept surfaces to provide the high quality surface finish demanded by customers. Cryogenic models require surfaces to be polished to a near mirror finish.
Increased test productivity since all model parts are trial assembled.