MIDLANDS

AEROSPACEISSUE 41. SUMMER 2016 MAGAZINE LIFT FROM THE MIDLANDS FARNBOROUGH 2016 ISSUE

MAA MEMBER COMPANIES ON BOARD NEWEST FIGHTER PROGRAMME – PAGES 9-10 PHOTO COPYRIGHT © ROLLS-ROYCE PHOTO

MAA CONFERENCE VIEW FROM INDUSTRY PRAISES BREAKS RECORDS WESTMINSTER NATEP BACKING Industry experts map out Call for transparency in Project companies highlight future directions – page 2 apprentice levy – page 11 business benefits – pages 12-13 Update ONLINE: WWW.MIDLANDSAEROSPACE.ORG.UK/NEWS NEWS ON THE WEB CLICK THROUGH TO THE MAA WEBSITE FOR CURRENT NEWS ON MEMBERS’ ACTIVITIES: ➔ The Daher Group whose aerospace divi- sion is an MAA mem- ber has confirmed its status as a leading equipment supplier by topping one billion euros in turnover for MAA BRINGS the first time. ➔ Derby-based Accrofab has supplied INDUSTRY equipment used to discover gravitational waves produced by TOGETHER black holes colliding. ➔ Leading surface solutions provider Rolls-Royce's Rosie Toogood presents a valuable point of view on a competitive supply chain. (Inset) Paul Kahn reviewed trends in global and UK Oerlikon Balzers aerospace. (Below) Flt Lt Jonny Dowen talks delegates through his Typhoon display routine. has received Airbus accreditation. The MAA annual Supported by gold shared knowledge and ➔ Dunlop Aircraft conference this sponsor UTC Aerospace perspectives from Tyres of Birmingham year set two Systems, the April event leading UK and global has received FAA ap- attendance records: for – now in its fourth year – companies including GE proval of its facilities the most delegates and attracted an audience of Aviation, GKN Aerospace, in China and the USA. the most speakers. 175 to the new Advanced Rolls-Royce and UTC ➔ Gardner Aero- It was also the first Manufacturing Training Aerospace Systems. space has posted a MAA conference to end Centre (AMTC) in Coventry, Delegates said the pre-tax profit of £6.7 with a flying display, where they heard 12 event was “very useful... million, reversing an £800,000 loss. albeit on video, courtesy speakers including two well organised [and] a of the final speaker, Flt from small companies. good balance of speakers Lt Jonny Dowen of 29(R) MAA operations and networking”. Squadron RAF Coningsby, manager Anne Esterson “Excellent location and last year’s Eurofighter said: “We were very and president of ADS, as a organisation,” said another. www.midlands Typhoon display pilot and pleased to have Paul Kahn, headline speaker.” “Excellent idea to finish aerospace.org.uk/news current display manager. the president of Airbus UK Other presenters with the fighter pilot!” MBO GIVES SIGMA NEW FOCUS AND DIRECTION

Leicestershire-based Sigma customers [and] taking the business to the are complementary to its pipe portfolio. Components is poised to next level”. Silverfleet Capital partner David take advantage of “exciting Long-time MAA member Sigma operates MacKenzie said the firm was “delighted” opportunities” following a management from four sites in the UK and two in China. to be partnering with Sigma, which he buy-out (MBO) backed by the private equity It is a global leader in the niche markets described as “a market leader with firm Silverfleet Capital. of aerospace pipes, ducts, fabrications and excellent growth dynamics”. Mark Johnson, Sigma’s founder and chief precision surface finishing. Its customers “We see an ideal opportunity to develop executive, said the £65 million deal with include Airbus, BAE Systems, Bombardier, Sigma, which operates in a fragmented former parent Avingtrans plc leaves Sigma Rolls-Royce and Safran. market, domestically and internationally.” in a good position “for broadening our In March 2016, Sigma bought pipe- manufacturing capabilities and developing manufacturing sites in Nuneaton in the UK www.sigmacomponents.com our relationships with new and existing and Xi’an in China from Rolls-Royce, which

02 MIDLANDS AEROSPACE HALL 1, STAND B90 FARNBOROUGH OPEN FOR BUSINESS

The Farnborough International Airshow bills itself as ‘the world’s greatest airshow’. This year, the arrival of four examples of the world’s newest fighter, the fifth-generation Lockheed Martin F-35 Lightning II Joint Strike Fighter (JSF), will help make sure Farnborough remains exactly that. Away from the JSF showstoppers, however, visitors can expect Farnborough to fulfil its promise by providing one of the best events in the aerospace calendar to meet customers and suppliers and do business – and the MAA is once again in the thick of it. The alliance and its exhibiting companies have their usual excellent location in Hall 1, within the UK Pavilion. The MAA stand, which covers 304 square metres, will be the home of 23 companies for a week – see the following pages for their details. The jury is still out on whether the Prime Minister David MAA will retain its unofficial title for Cameron, pictured (right) talking with Sigma's Mark the most companies exhibiting with a Johnson (left) and Mark regional alliance from anywhere in Lambert, was among the world. VIP visitors attracted “Those who exhibited with us or to the MAA stand at Farnborough 2014. visited in 2014 will remember how This year, the stand's the MAA stand was brimming with MBO GIVES SIGMA NEW FOCUS AND DIRECTION design again turns the business meetings for days on end,” space between pods said chief executive Dr Andrew Mair. into an attractive and inviting area to meet, “We have every reason to believe our greet and talk business, stand will have the same level of activity as visitors in 2014 this year, which can only be good for discovered (above). our companies.” The show opens on 11 July for seven days. The first five days are trade-only; the weekend of 16-17 July are public days. VISIT US AND OUR EXHIBITORS IN HALL 1, STAND B90

MIDLANDS AEROSPACE 03 FARNBOROUGH 2016 SEE US IN HALL 1, STAND B90

AN OVEN FOR NEW ALLOYS GET EVERY NEED AIRSHOW LAUNCH

Aluminium alloy heat treatment Aluminium Special Products specialist AHT is in its element (ASP) is introducing a range at Farnborough. of advanced, ultra-high The biggest occasion of the performance aluminium alloys BREAKTHROUGH FOR global aerospace community at Farnborough. Produced by INVENTORY HANDLING MAJOR INVESTMENT is “a fantastic opportunity to Powder Light Metals GmbH, EXCELLENCE AND BOOSTS CAPABILITIES meet potential new customers the range features low and FAST TURNAROUND A new Visual Inventory with the aluminium sector,” AHT controlled thermal expansion Optimisation System (VIOS) Columbia Precision is director Ian Perks said. “Being alloys for aircraft and space software demonstrator is the Midlands-based Alloy Wire at Farnborough this year a week-long event, it will allow applications. highlight of ConsultAvila’s International (AWI) is a critical to promote its enhanced me to spend time with existing For more than 30 years, stand at Farnborough. partner to the aerospace supply capabilities following its customers and offer help with ASP has supplied bespoke The demonstrator, developed chain, supplying precision, investment of several million regards to any current and aluminium alloy raw materials with the help of a NATEP grant, drawn, flat and shaped wire dollars in modern plant and future projects.” and components for aerospace, displays part stock levels, in more than 50 nickel ‘high human resources. AHT offers various sizes of automotive and general replenishment and consumption performance’ alloys. The Birmingham-based heat treatment ovens with a engineering applications. It on a management ‘dashboard’ The company, which firm has recently added two process capacity of five tonnes sources raw materials from using data visualisation to celebrates its 70th anniversary Matsuura 5-axis prismatic CNC to cater for the needs of the specialist global manufacturers facilitate dynamic inventory this year, provides its global machines, a Mazak Megaturn sector, ranging from very small for demanding and specific planning and control. client base with access to a and Studer twin-spindle CNC items all the way through to applications. ConsultAvila director Dudley comprehensive range of high grinder, all of which add to large structures such as landing In addition, ASP offers a full Wood said the VIOS “is based corrosion resistant and high Columbia’s unmanned state-of- gear. range of processing options on concepts we’ve been working temperature performance alloys the-art manufacturing capability. A Nadcap accredited in-house with a network of on for many years, such as commonly used in aircraft fire Columbia has been supplying company with more than local sub-contract sources for segmentation, trend analysis, detection, engine retaining rings, complete precision engineering 40 years’ experience as a finishing, testing etc. forecasting and alerting. fasteners, high temperature solutions to demanding markets subcontractor, AHT prides itself The company has developed “Inventory is a big issue seals and engine compression including aerospace and on being the preferred supplier expertise in machining tubular for many businesses in this springs. defence for more than 35 years. to many aerospace primes. components to exacting sector, particularly if they Approved by BAE Systems, Operations director dimensional tolerances as have complexity, variety and Raytheon Jets and Westland Ted Yarnall said the firm Contact: Ian Perks required for aircraft seating, volume, and aged stock. In Corp, AWI produces 0.025mm “is committed to ongoing T: +44 (0)7712 397978 military and commercial. It offers our experience, business to 21mm bespoke wire in investment into NPI, new E: [email protected] deep hole drilling to achieve can release more than 15% exotic alloys, including Nimonic technologies and training to www.alloyheat.co.uk variable wall thicknesses, of the working capital while 90, Inconel 600, Nimonic 75, meet engineering and customer shaped internal chambers etc, maintaining and even improving Waspaloy, Titanium Grade 5 and requirements. This enables us backed up with the latest CMM service levels. Monel 400. to cater for existing and new measuring and process control “We’ve talked to a lot of Sales executive Tom Mander clients’ requirements while technology. people, shown them early said: “We’ve built our business still competing with low cost demonstrators and found on quality and fast turn-around. economies.” Contact: David Robinson exceptional interest.” Our manufacturing policy is The company’s specialist T: +44 (0)7768 835470 ConsultAvila and its partner AS9100 ‘Aerospace & Defence’ skills include the development E: davidrobinson@aspgroup. CANDA Systems expect to have accredited and, with our ‘no and production of complex co.uk a market-ready package within minimum quantity’ policy, it prismatic parts that can be www.aspgroup.co.uk six months. saves customers money and supplied in kit form and as helps them meet fluctuations in complete tested sub-assemblies. Contact: Dudley Wood volumes.” T: +44 (0)7958 796375 Contact: Ted Yarnall E: dudley.wood@consultavila. Contact: Tom Mander T: +44 (0)7970 872077 com T: +44 (0)1384 262022 E: [email protected] www.consultavila.com E: [email protected] www.columbia.uk.com www.alloywire.com

04 MIDLANDS AEROSPACE FARNBOROUGH 2016 SEE US IN HALL 1, STAND B90

FORUM GIVES ITS DELCAM PREPARES MEMBERS A BOOST FOR INDUSTRY 4.0

Returning to Farnborough after Delcam Professional previous successful airshows Services (DPS) is at are members of the Coventry Farnborough to promote its and Warwickshire Aerospace enhanced range of products Forum (CWAF). and services. “In contrast to our rather long- DPS has been offering WORLD-FIRST IN JET CUSTOMER BENEFITS winded name, we are a group customised products and TRAINING SYSTEMS ANSWER FOR EXOTICS, FROM VALUE STREAM of unusually forward-thinking services for aerospace DELICATE STRUCTURES aviation industry manufacturers manufacturers and DART is at Farnborough to who are key suppliers to global MRO companies for more CW Fletcher is at Farnborough promote its end-to-end jet trainer Electro-discharge machining aerospace companies,” said than 15 years. Its capabilities to showcase the benefits system – a world-first. (EDM) specialist Electro- spokesman Jason Aldridge, now extend to the factory- to customers of its new DART responds to the Discharge is at Farnborough managing director of Arrowsmith of-the-future to automate, Value Stream approach to challenges of cost and fleet to talk about the benefits and Engineering. integrate and optimise workflow manufacturing. diversity that military flight advantages of its wire and spark “By harnessing our vast with technologies including The shift to a Value training operators face in taking erosion capabilities. engineering knowledge and generative design, materials Stream structure builds on its students from Basic to Advanced The company subcontracts experience, together with our technology and simulation as engagement with the Sharing flying training and finally Lead-In its services to Tier 1 companies diverse production capability, well as advanced manufacturing in Growth programme and Fighter Training (LIFT) and in aerospace, where its we are able to offer innovative methods such as robot CW Fletcher’s commitment to Operational Conversion on a competitive advantage lies in and cost-effective solutions to programming and additive focusing on its core product front-line fast jet. the ability to process exotic many aerospace manufacturing manufacturing (AM). groups: machined from solid, “Our family trainer concept materials and delicate structures challenges.” DPS services range machined fabrications and of different wing and engine such as honeycomb. What makes CWAF so from supplying extra actuator unison rings. options based around a Electro-Discharge runs a unusual is the way its members design, programming and In addition, CW Fletcher common fuselage, cockpit and busy operation with more than help each other find solutions machining resources to is keen to talk about its new ground-based training system 30 machines installed. Its latest to problems regardless of developing software to automate partnership with an experienced will meet the requirements wire-cut machine can handle whether they have a financial manufacturing or establish new Indian engineering company of all flight training phases, rings up to 1.2m in diameter and interest in the outcome. This processes for novel designs. which business development specifically for lower-cost and 700mm thick, which makes it gives CWAF members access Recent projects from DPS manager Richard Phillips said export customers,” said director ideal for segmenting or profiling, to the expertise and R&D of include partnering with Technicut “places us in the enviable Tristan Crawford. including honeycomb diameters. companies 10 times their size. to revolutionise blisk machining position of being able to Uniquely, DART can amortise Four-axis CNC die-sinking For their clients, it brings the efficiency, delivering a 51% provide high-quality machined the development costs of the machines are used for benefit of finding optimum saving in cycle time and 45% fabrications, incorporating system across sales to basic, angled holes, slots, stepped production solutions far more reduction in milling cost. This machined components at a advanced and LIFT jet trainer honeycomb diameter or complex quickly and cost-effectively than 804mm diameter, 31 bladed significantly reduced cost markets. This in turn will allow hard-to-machine features. might otherwise have been Ti-64 blisk took just 35 hours base, should our customers DART to reduce the acquisition “EDM doesn’t need a lot of achieved. to rough and finish mill using choose this.” cost of the system. clamping force,” said general PowerMILL and Technicut’s CW Fletcher operates in a Ninety-per-cent commonality manager Rupin Vadera, “which Contact: Jason Aldridge barrel tooling technology. wide range of material types and across DART airframes will makes it ideal for processing T: +44 (0)7810 540650 up to 2m in size, with customers significantly reduce the spares easily-damaged structures like E: [email protected] Contact: Martin Boon including Kawasaki Heavy count, instructor training and honeycomb. www.cwaf.co.uk T: +44 (0)121 766 5544 Industries, GKN Aerospace, technician training costs across “The more exotic or harder E: [email protected] Siemens and Rolls-Royce. the fleet. the material, the better. As long www.delcam-services.com “We’re a safe partner for any as it’s conductive, we’ll cut it.” customer,” said Phillips. Contact: Tristan Crawford T: +44 (0)7948 910146 Contact: Rupin Vadera Contact: Richard Phillips E: [email protected] T: +44 (0)7767 243632 T: +44 (0)7713 566079 https://dartjet.biz E: rupin@electro-discharge. E: [email protected] co.uk www.cwfletcher.co.uk www.electro-discharge.co.uk

MIDLANDS AEROSPACE 05 FARNBOROUGH 2016 SEE US IN HALL 1, STAND B90

CREATIVE THINKING SECTOR INSIGHT MEANS YIELDS SOLUTIONS TOP RECRUITMENT

IPI Solutions celebrates more Jonathan Lee Recruitment has than 10 years of innovation been supplying the aerospace, in ‘Computer Aided Quality’ defence and aviation sectors within the aerospace, defence with exceptional people for more PRODUCT DATA and other high-integrity than 38 years. INTEROPERABILITY manufacturing sectors. IPI’s Offering ‘Solutions approach is simple, through through Understanding’, creative thinking and working To remain competitive, the consultancy provides closely with customers to solve aerospace manufacturers are best-in-class recruitment and TOP SOLUTIONS SPRING CHALLENGE: industry-wide issues. implementing model-based talent management services to FOR MACHINING ANY TAKERS? Recognising a need within enterprise, advanced simulation clients globally. With many of the electronics industry, IPI and PLM initiatives supported our consultants having direct ITC, a leading UK manufacturer, by best-in-class engineering G&O Springs is once again developed a solution to manage experience in the sectors for stockist and distributor of systems. However, data extending an invitation to the complexity of PCBA Printed which they recruit, we take pride precision cutting tools and interoperability issues can all Farnborough visitors and Circuit Board Assembly FAI in our in-depth understanding associated equipment, returns impede progress. exhibitors to bring them any AS9102 reports. of the skills, experience and to Farnborough on a mission to ITI solves complex spring design or technical Working with an OEM attributes that clients require help its customers produce their interoperability problems, problems they may have. supplying multiple industry in an increasingly competitive products faster, more reliably supporting key aspects of PLM It’s an extension of the sectors globally, IPI integrated marketplace. and better. and MBE including: design, company’s free design and a web solution to receive, Operating with In addition to manufacturing analysis, change management, technical advice service that has evaluate, and efficiently manage professionalism and integrity its own Cyber Series range of certification, long-term archival helped make G&O the ‘go-to’ their supplier PPAPs. through a partnership approach, high precision carbide and PCD and technical data packaging. name for anything to do with IPI has a comprehensive we provide true consultancy to tooling, and special-to-product “Aerospace customers springs. range of applications to manage our clients and candidates alike. cutting tools, in its state-of-the- demand that their engineering “We have our technical team APQP/NPI, PPAP, FMEA, Managing consultant art manufacturing unit, ITC is and manufacturing technologies on hand to solve any issues SPC, Inspection Planning/ Matthew Heath said: “We are also the main UK agent and enable interoperability from you may have,” said managing Control Plans and Gauge R&R fully committed to supporting our stockist for Widia solid carbide design to sustainment. ITI is director Steve Boyd. “If you processes. clients in meeting the demands and indexable cutting tools, and in a unique position to offer bring along a problem they CEO and founder Brian of increases in build rates and for the world-renowned BIG CAD migration, validation, and cannot solve on site, we’ll give Harvey said: “Our solutions passenger growth. Finding and KAISER range of boring tools integration solutions that can you a free bottle of champagne.” bring significant benefits to retaining the best people is more and tool holders. be applied across the product G&O has a slightly different individual suppliers through critical than ever to success in “We keep over 100,000 lifecycle,” said Andy Chinn, approach to the manufacture entire supply chains, from this skills-short market.” tools on the shelf for immediate commercial director, ITI. of springs. Boyd said: “All the extracting and auto bubbling Come and talk to our expert despatch,” said IT coordinator “No other company has springs we produce are mandrel inspection requirements from team at this year’s show. Simon Horseman. “We are the level of experience and coiled by skilled operators to the 3D models or 2D drawings and confident our range of world- focused approach to solving tightest of tolerances.” When importing results from; CMM, Contact: Matthew Heath class tooling, combined with interoperability issues." you visit the stand, he’ll explain digital tools or even importing T: +44 (0)7773 643950 our expertise, can improve any ITI is using Farnborough to the benefits of this approach. handwritten results, captured E: [email protected] and digitally imported.” machining process. meet customers and discuss www.jonlee.co.uk/aerospace- “We believe good customer how it can help integrate Contact: Steve Boyd defence-and-aviation-jobs service is vital, and our staff design and analysis processes, T: +44 (0)1527 523764 Contact: Brian Harvey are trained to provide expert facilitate greater collaboration, E: [email protected] T: +44 (0)1623 272500 ext 1 support, whether you know and provide validation to ensure www.springs.aero E: brian.harvey@ipi-solutions. com exactly what you need, or need companies can trust the integrity www.ipisoftware.com guidance from start to finish.” of their CAD data.

Contact: Andy Boyles Contact: Andrew Chinn T: +44 (0)7787 240055 T: +44 (0)7989 410513 E: [email protected] E: [email protected] www.itc-ltd.co.uk www.iti-global.com ➧ ➧ ➧ ➧

16-22 July 2018

06 MIDLANDS AEROSPACE FARNBOROUGH 2016 SEE US IN HALL 1, STAND B90

TWO CASTING OPTIONS FROM ONE LOCATION

Maycast-Nokes Precision CHOICE IN YOUR Engineering is a leading CERTIFICATION NEEDS supplier of fully finished, machined precision castings. Kiwa UNAVIAcert is at The company is one of the only Farnborough spreading the UK foundries capable of offering message of choice in who you DISTINGUISHED RECORD precision sand and investment/ work with for your aerospace lost wax castings from a single IN SPACE SCIENCE and defence certification needs. location. A benchmark for the Using rapid prototyping The University of Leicester is aerospace certification market, techniques, it can supply at Farnborough to promote its Kiwa UNAVIAcert originates castings on short lead times long and distinguished record in Italy but now is active for initial trials or fit, form and of discovery in space science: throughout Europe and used by function tests. “We can then every year since 1967 has seen 130 companies for 91xx series supply production quantities, ENGINEERING INNOVATIONS IN SHEET METAL a Leicester-built instrument of standards. from hard tooling, of machined, operating in space. “We operate best industry finished and assembled First-time exhibitor MJ Sections is promoting its latest engineering Space-related work at practice and the highest castings,” said sales director innovation in sheet metal at Farnborough. Leicester covers upstream: levels of client service,” said Dave Blower. The company, a specialist in precision-formed sheet metal hardware, instruments, UK marketing coordinator Maycast-Nokes complements fabrications and machined components to the UK and global missions and applications. Our Karen Stageman. “We have its extensive on-site casting, aerospace markets, is now able to replace traditionally expensive Space engineering expertise comprehensive experience machining and testing facilities machined forgings with sheet metal rings – and hold critical makes us the home to a wide- in safety and mission-critical with comprehensive finishing tolerances where needed. ranging expertise in design of systems as well as component and assembly capabilities. “The driving forces behind this are the significant lead time and mechanical, thermal and optical manufacturing and processing. “We are well versed in most cost reductions that are possible,” said commercial manager Steve systems, power electronics and We’re here to help.” surface treatments associated Cresswell. “The finished product could actually cost less than the embedded systems. We develop The company provides with aluminium components,” forged starting ring. systems which can operate assessment and certification said Blower. “We also offer “We look forward to showing you samples on our stand.” in extreme environments for for AS/EN/JISQ9100: Quality mechanical assembly work. The innovation in sheet metal rings adds to MJ Sections’ diverse extended periods without the Management Systems – for “This means from a single range of special processes – all NADCAP approved – including need for servicing. Development, Production, purchase order, clients can welding, NDT, vacuum heat treatment, with brazing coming in 2016. We are conducting research Installation and Service source fully machined, finished The company’s current portfolio of parts includes rolled rings, into radioisotope power sources Organisations; ‘9110 Quality and sub-assembled castings, rolled stringers for airframes, precision sealing rings/wires/ for future European space Management Systems – which are ready to go straight honeycomb rings, pressed brackets and fabrications, machined exploration missions, such as for Aviation Maintenance to production.” parts made from turning and milling (3 and 5 axis). NUCLEAR power sources. Organisations; ‘9120 Quality “We’re proud to include leading airframers and engine makers Our specialist research in Management Systems – for Contact: Dave Blower among our customers, providing a fast and proactive response to solar winds and space weather Aviation, Space and Defence T: +44 (0)7814 498051 their needs,” said Cresswell. are conducted with spacecraft Distributors. E: [email protected] and ground-based facilities; European NABs have www.maycast.co.uk Contact: Steve Cresswell Leicester is also a destination agreement to allow other CBs T: +44 (0)7810 158360 of choice for planetary material to operate abroad. UKAS has E: [email protected] analysis, understanding of an agreement with Accredia, www.mjsections.co.uk planetary environments and permitting UNAVIAcert to Earth Observation and its operate in the UK. associated applications.

Contact: Adrian Woodridge Contact: Dr Sarah Stevens T: +44 (0)7718 570565 T: +44 (0)116 223 1929 E: [email protected] E: [email protected] www.kiwa.co.uk/aero www2.le.ac.uk/institution/space

GET INSIDE THE BIG FOUR The simple solution to taking your EUROPEAN AEROSPACE marketing message to the heart of international aerospace MARKETS WITH THE MAA Contact: [email protected]

MIDLANDS AEROSPACE 07 FARNBOROUGH 2016 SEE US IN HALL 1, STAND B90

EXPANDING ROLE IN AVIATION MARKET STEEL FOR EVERY NEED IN AEROSPACE Spincraft and Enginetics are at Farnborough to Acciaierie Valbruna has been showcase manufacturing producing steel for more than processes and hardware 90 years and is at Farnborough components integral to to promote its work within their expanding roles in the global aerospace and the aviation market. defence industries. Spincraft’s current The company produces more Airbus contract includes than 180,000 tonnes of single-piece spun and machined lipskins for A320neo nacelles. stainless steels, duplex steels, This complements earlier A320neo awards of the geared turbo fan nickel alloys and titanium long FOCUS ON INNOVATIVE LIGHTWEIGHT COMPONENTS engine, and five-piece exhaust plug and nozzle sets. products per annum from Enginetics’ extensive three plants, in Vicenza and Sigma Components returns to Farnborough with the latest metal-forming and Bolzano, Italy, and in the USA innovations from a range of R&D programmes to develop lightweight precision machining at Fort Wayne, Indiana. It offers aerospace components. capabilities support a more than 700 special steel The Sigma Lite range is the result of Clean Sky, NATEP and broad range of next qualities in a range of sections. AMSCI-funded programmes and includes Sigma’s ground-breaking generation engines Valbruna’s ISO-accredited COMPipe technology – a composite pipe for aero-engines that including GTF and LEAP. quality systems, philosophy offers up to 50% weight savings over traditional components – To support increased and expertise permeate every redesigned end fittings produced using additive manufacturing (AM) volume, a new 7,246 aspect of production. This techniques, and composite drive shaft technologies. square metre Spincraft ensures the highest quality Mark Johnson, founder and CEO of Sigma Components, said: facility opens this steel which meets the “The team has been working hard over the past few years to summer. The plant, located in the US state of Wisconsin, will increasing demands of its develop new technologies to develop lighter, more fuel-efficient specialise in aluminium close-tolerance aviation components. high-tech markets with improved components and we’re excited that several of these projects – which Together, Spincraft and Enginetics make up Standex performances, integrity, reliability use both composite and metallic materials – are now moving into International’s Engineering Technology Group. With seven facilities and machining consistency. production stages. Investment in developing the next generation of throughout the UK and US, the group provides global manufacturing The company’s extensive and aerospace technologies is paying dividends for our business and solutions via collaborative engineering efforts. Precision metal strategic distribution network we’re proud to be building a world-class new product introduction forming technologies are supplemented with vertically integrated is its cornerstone in the global capability across the business. manufacturing processes to support aviation, defence and space market, allowing a worldwide “As the first show since our recent change in ownership, and system markets. commercial presence as well also the first we’ve attended since completing the acquisition of as a continuous service to Rolls-Royce’s pipe business earlier this year, we’re looking forward Contact: Steve Ireland customers. to talking with current and new customers about our increasing T: +44 (0)7780 997811 It has UK service centres in capacity, both in the UK and China, and our expanding capabilities, E: [email protected] West Bromwich, Sheffield and including the creation of centres of excellence for pipe, ducting and www.StandexETG.com Manchester. fabrication manufacture here in the UK.”

Sigma Components manufactures ducting, fabrications, sheet Contact: Nick Bate details, airframe sub-assemblies, rigid pipe assemblies, composite T: +44 (0)121 553 5384 components, machined items, specialist fasteners, assembly and E: [email protected] build fixtures, finishing and polishing services for aerospace OEMs www.valbruna.co.uk and Tier 1s. With manufacturing facilities across the UK and in China, the business can also manage the supply chain on the customer’s behalf, delivering lowest-cost, lowest-risk solutions at every stage of the product lifecycle.

Contact: Mark Lambert T: +44 (0)7833 595213 E: [email protected] www.sigmacomponents.com

Become a member of the MAA and join the 300+ other companies and organisations who are already enjoying the benefits of belonging to one of Europe’s largest aerospace industry trade groups. It costs your company only £495 per year if you are in the Midlands or £690 if not. ■ Contact: [email protected]

08 MIDLANDS AEROSPACE HALL 1, STAND B90 COVER STORY F-35 JOINT STRIKE FIGHTER

At the heart of the Rolls-Royce LiftSystem is the fan capable of generating more than 20,000 lbf of thrust. (Photo: Rolls-Royce).

MIDLANDS UPLIFT

THE LOCKHEED MARTIN F-35 LIGHTNING II IS BOUND TO BE THE HIGHLIGHT OF ANY AIRSHOW IT ATTENDS, AND FARNBOROUGH 2016 IS NO DIFFERENT. WITH AS MANY AS FIVE EXAMPLES OF THE FIFTH-GENERATION FIGHTER EXPECTED ON THE GROUND AND IN THE AIR, ITS IMPACT COULD HARDLY BE GREATER.

The global supply chains of prime The F-35B’s LiftSystem was developed contractor Lockheed Martin and its and built by Rolls-Royce to a Lockheed main partners Northrop Grumman Martin design. Rolls-Royce says this and BAE Systems will be in a celebratory system is “the world’s only vertical lift mood as the fruit of their efforts goes technology for fighter jets in production” through its paces at Farnborough. and a “descendant” of the Pegasus engine. The F-35 programme began in earnest The LiftSystem comprises the LiftFan, in 2001 with Lockheed Martin’s selection driveshaft, three-bearing swivel module as the main contractor for the Joint (3BSM) and roll posts. Strike Fighter. Teaming up with Northrop The LiftFan is a 50in (127cm) fan capable Grumman and BAE Systems, Lockheed of generating more than 20,000 lbf of Martin started development. Five years Dunlop manufactures main gear tyres for the F-35B. thrust. It is connected by the driveshaft to later, in 2006, the first production aircraft the aircraft’s Pratt & Whitney F135 engine rolled off the assembly line in Texas. the centre of attention for UK suppliers. to produce the forward vertical lift. F-35A deliveries started in 2011, with Derby-based Rolls-Royce is the first The other parts of the LiftSystem are the the short takeoff vertical landing (STOVL) among many Midlands companies with 3BSM which redirects main engine thrust variant, the F-35B, following in 2015. important roles on the programme although downwards to provide rear vertical lift, and The F-35B is expected to be well- its work takes place largely in Bristol and the wing-mounted roll posts which stabilise represented at Farnborough; it is the variant Indianapolis. A partial list of others, which the aircraft in hover with up to 1,950 lbf of that will be flown by the RAF and Fleet Air includes UTC Aerospace Systems (UTAS), thrust each. Arm. Thanks to the ground-breaking Moog, Dunlop Aircraft Tyres, Icon Polymer Rolls-Royce said the LiftSystem uses Rolls-Royce technology that gives it its and ASP, reflects the diversity, capability “the latest in digital control and fan system STOVL capabilities, it will without doubt be and depth of the Midlands supply chain. technology” to deliver the STOVL (to page 10)

MIDLANDS AEROSPACE 09 COVER STORY F-35 JOINT STRIKE FIGHTER capability “with minimal impact on total airframe weight”. Moog in Wolverhampton subcontracts to Rolls-Royce for the LiftFan actuation system. Components designed and manufactured by Moog include the transfer gearbox and 3BSM actuation for the aircraft’s thrust vector control. A spokesman said the F-35 is a “big programme in Wolverhampton and very significant” for the Moog military aircraft group in the UK overall. “The total content, on all of the aircraft variants, is very significant for the company as a whole,” he added. Other major military programmes for Moog in Wolverhampton are the Eurofighter Typhoon and Saab Gripen. In the US, the company has a long and successful history with fast jets including the Boeing F-15 Eagle and F/A-18 Hornet. Moog-produced components of the F-35B LiftFan actuation system. (Photo: Moog). Also based in Wolverhampton, UTC Aerospace Systems (UTAS) is one of the production next year. UTAS employs close to but has been recognised by the prime for its biggest single contractors in the UK on 100 skilled machinists on F-35-related work. flawless delivery and quality performance the F-35 programme aside from BAE Wolverhampton-based Comar over a full year. Systems and Rolls-Royce. A specialist Engineering designed and made eight Tom Ludwell, the company’s head of in actuation systems, UTAS supplies a different test rigs for the various actuation business development, said the accolade range of equipment, the biggest, most systems. was “testament to Icon Polymer’s unique complex, being the Weapons Bay Door Also on the programme is Birmingham- working ethos and global capabilities, as Drive System for programme partner based Dunlop Aircraft Tyres (DAT), an approved supplier to all of the major Northrop Grumman. A company spokesman which describes itself as the world’s only manufacturers and Tier 1 suppliers”. described it as a “significant” component in dedicated aircraft tyre manufacturer. DAT Icon Polymer supplies the ducting used terms of both size and value. has a successful history of supporting in the environmental cooling system on Additionally, the company supplies a STOVL aircraft, having previously provided the F-35. The company supplies Lockheed suite of Utility Door actuators to Lockheed tyres for the British Harrier jet and to the Martin through its accreditation with BAE Martin, for the refuel probe door, the gun US for the AV-8B. Systems. It also supplies a number of other port and gas purge doors, the lower doors Building on this heritage, the company customers that support the F-35 platform. for the Rolls-Royce LiftFan, auxiliary air was selected to supply the mainwheel radial The Midlands has strength in numbers inlet doors, and the arrestor hook door and tyres for the STOVL version of the F-35. More among its SMEs whose capabilities across a uplock for the carrier-based variant, the than 400 F-35Bs are due to be delivered to wide range of skills and services land them F-35C. It also supplies the locking system, armed forces in Italy, the UK and USA. roles on many global programmes. One of to BAE Systems based in Samlesbury UK, Further down the supply chain, them is Aluminium Special Products (ASP). for the 3BSM on the STOVL variants. Nottinghamshire-based Icon Polymer not ASP supplies rocket motor cases produced The spokesman said the company is only supplies lightweight silicone ducting to from high alloy tube to Martin-Baker for the preparing for the expected ramp-up in Lockheed Martin on the F-35 programme US16E ejector seats used in all F-35 variants.

10 MIDLANDS AEROSPACE THE VIEW FROM WESTMINSTER “The lack of detail makes it difficult for firms and training providers to plan...” Iain Wright MP, chair of the BIS select committee, urges members of the Midlands aerospace community to share their views with his committee.

After being elected to the chair the select committee are very keen to of the Business, Innovation and listen to your views and act as an effective Skills Select Committee by the voice to government, amplifying as much House of Commons after the general as possible your concerns. election last year, my objectives for the Our forthcoming inquiry into local work of the committee are clear. Our job economic devolution, with particular is certainly to scrutinise, question and if emphasis on the Midlands Engine and necessary criticise government policies in Northern Powerhouse initiatives, will business and skills. need your input and I invite you to give us But business doesn’t want parliament your thoughts as to whether the Midlands to oppose simply for political purposes. So Engine actually has an impact – positive or our role is to work to add value – to ensure negative – on your business. that Britain has the policies and business In the end, however, success or failure environment which will allow more wealth “We have to remain vigilant of the aerospace industry in the Midlands to be created, with firms growing and will rest on the ability to secure the winning more orders here and overseas and ensure that the aerospace right skills. The government had placed and employing greater numbers of people industry in the UK remains apprenticeships at the heart of its skills with high skills, providing the knowledge policy, with the apprenticeship levy the and innovation which is essential to innovative, highly skilled and means by which companies pay for those success for the UK in the competitive ever more productive.” apprentices. global economy. The industry has a good track record The aerospace industry is one of However, other countries such as Brazil in securing apprenticeships but skills the best examples of a successful and and China are eager to capture market share shortages remain, constraining the growth modern industrial sector for Britain. The in the aerospace industry and are snapping potential of the sector. We still have no Aerospace Growth Partnership (AGP) at our heels. We have to remain vigilant and detail on the levy, even though it will be is a fantastic illustration of government ensure that the aerospace industry in the UK deducted from large firms’ payroll in less and business working closely together to remains innovative, highly skilled and ever than a year. The lack of detail makes it set the long-term goals of the industry more productive. difficult for firms and training providers to in improving productivity, accelerating Clusters are important in this field. Firms plan in a sensible and coordinated way. We innovation, coordinating the supply chain collaborating as well as competing, and on the select committee, working closely and maintaining and raising skills levels. sharing knowledge and examples of best with our counterparts on the Education The potential prize for the industry is practice, can raise the productivity and Select Committee, are investigating huge. Something in the region of 29,000 profitability levels of the entire supply chain apprenticeships, and we would really value additional aircraft are expected to be in an area. That’s why I warmly applaud the your experience and insight. commissioned and delivered around the work of the Midlands Aerospace Alliance, world in the next 15 years, with a potential helping to give a coordinated voice to www.iainwrightmp.org.uk value of almost £3 trillion. the firms in the sector in the region. We on

MIDLANDSMIDLANDS AEROSPACE AEROSPACE 13 11 NATEP ASSESSING RESULTS LASTING BENEFITS NATEP HAS NOW REACHED THE PEAK OF ACTIVITY WITH 100 PROJECTS LIVE. BUT WHAT LONG-TERM BENEFITS HAVE PROJECT PARTICIPANTS TAKEN FROM THE PROGRAMME? MIDLANDS AEROSPACE TALKS TO FOUR COMPANIES FOR WHOM NATEP HAS MADE A DIFFERENCE.

NATEP – the National Aerospace it is very rewarding to see exciting and performance and cost of power modules, Technology Exploitation Programme promising new technologies which are improve standardisation and integration – is a modern success story that again helping our aerospace supply chain to while reducing component size and weight. proves the wisdom of an old proverb: great compete globally,” he said. As an extra benefit, Semelab has developed things can grow from the smallest seeds. Midlands firms are well represented the ability to produce four configurations of By supporting research and development among NATEP projects, with many acting as the device with one tool set, and in a single in the supply chain, NATEP has had a hand project leads. process. in the creation of innovative technologies “Our business is very much a niche area and solutions across the breadth of the Configurable double-sided cooled for aerospace, and volumes are low,” said aerospace industry whose potential impact integrated power module Mills. “This is allowing us to gear up for is huge. Along the way, it has helped small For the Leicestershire-based semi- higher-volume manufacturing and compete companies begin to understand how to conductor specialist Semelab, part of the on that scale using our current equipment.” realise their own creative potential in a TT Electronic Group, R&D underpins its The NATEP approach brought unexpected tough market. corporate culture as it seeks to keep ahead business benefits to the company's R&D It was ATEP – a Midlands forerunner to of the market and maintain its status as an capabilities. “One of the good things NATEP – that demonstrated that “relatively expert in its field. was the workshops they arranged,” said modest, well placed grants seeded into the Under its 18-month NATEP project, Mills, singling out sessions on intellectual supply chain, and backed by expert help Semelab and project partner Pre-Met property (IP) and roadmapping. “These and mentoring, could produce remarkable are designing and manufacturing a types of business-level workshops are results,” said Peter Knight, MAA technology demonstrator of a configurable power good, particularly for small companies.” manager for NATEP. module for end-user Rolls-Royce. “In some cases these results had a R&D manager Liam Mills said the Process optimisation for aerospace alloys transformative effect, particularly for £254,000 project is at its halfway point and ANT Industries was one of three small smaller businesses. on track to finish next year. Midlands companies that formed a “As the first tranche of NATEP projects The project’s objective is to achieve consortium to work with the Manufacturing now begin to reach successful conclusion, significant improvements in reliability, Technology Centre (MTC) on process

Semelab and project partners (from left): Simon Turvey (Rolls-Royce), Prof Shankar Madathil (Sheffield University/Rolls-Royce), Adegoke Gbadeyan (Rolls-Royce), Liam Mills (TT Electronics Semelab), Steve Haynes (Pre-Met), Dr Graham Bruce (Rolls-Royce), Phil Peeler (Pre-Met), Ben Peeler (Pre-Met). Dr Bruce is no longer on the project team.

12 MIDLANDS AEROSPACE NATEP ASSESSING RESULTS

AFP technology offers potential cost and performance advantages. (Photo: Heraeus Noblelight). optimisation for aerospace alloys. Its SME to find the time for R&D,” said Rowley. new technology and “allowed us to invest to partners in the £180,000 NATEP project “When you can sit with a team of experts, speed up the journey to a high technology were Arrowsmith Engineering and you get new ideas that challenge what you readiness level,” he said. Technoset, working with end-users do. For us, that was a bonus. The long-term benefit of the NATEP Pattonair and ITP. “We would definitely go into a NATEP project will be “UK jobs, created and ANT’s part of the project focused on the project again.” secured for the future, putting the UK in the machining of large-diameter, thin-section lead for this technology.” rings for engines. Xenon pulse technology Managing director Shaun Rowley said in fibre placement Novel Miniature Actuator the company was looking for a more Heraeus Noblelight used its 18-month, Engineering design specialist CNR Services generic understanding of how materials £290,000 NATEP project to demonstrate International led this £300,000 NATEP project behave during machining. “With accurate the use of xenon flash technology as an to design and demonstrate an actuator for measurement of the relaxation in the intelligent heat source in automated fibre first and business class aircraft seats. material during machining, we can placement (AFP) for processing composite CNR managing director Chris Reckless apply calculated compensation error materials for aerospace applications. said success in testing the ‘Novel Miniature (CCE) – effectively machining incorrectly, ‘Xenon Pulse Technology in Fibre Actuator’ to aerospace specifications points knowing the part will be correct when it’s Placement’, carried out with partner Hexcel to a potential game-changer in its class. completed,” he said. Composites for end-user Rolls-Royce, He said the new device is lighter, cheaper Though not a new technique, taking a concluded in March 2016 and is already and uses less power. “Once this gets scientific approach to CCE allows ANT attracting interest among OEMs. productionised, the weight saving alone to shortcut the normal 1-2 year product AFP technology is widely used in will run into billions of dollars a year. It’s a development process to a few months. aerospace, said technical director Jeremy massive win for the operators.” Rowley said ANT is applying the newly Woffendin, and offers potential cost and NATEP gave CNR and its partner Midland acquired information for metals ranging performance advantages. “We see concrete Aerospace an opportunity to develop a from aluminium to inconel alloys throughout commercial opportunities arising from the difficult concept. “It’s always a challenge its business to improve its manufacturing project work” with potential in other sectors to improve on a solution that’s already out efficiency. An immediate result has been a as well, he said. “We’re working with key there.” He would have no hesitation to run long-term contract with ITP. OEMs to fully integrate our system into further projects under NATEP. For ANT, the NATEP project provided a their products.” gateway to the technology and experts at NATEP’s involvement lowered the www.natep.org.uk the MTC. “It’s always a challenge for an financial risk associated with developing a

MIDLANDS AEROSPACE 13 PROFILE VIEW FROM THE MAA BOARDROOM

I think the aerospace industry is

unique... I like the untapped potential

Klaids Lafon de Ribeyrolles, executive vice-president, Infrastructure and Services Purchasing at Rolls-Royce, finds good relationships with suppliers can sometimes be more helpful than the contractual position.

DID YOU HAVE A CAREER GOAL WHEN YOU HOW DO YOU VIEW THE GLOBALISATION OF WERE A STUDENT? CIVIL AEROSPACE? I wanted to be a fighter pilot, passed the It’s inevitable. We need to embrace it and selection of Ecole de l’Air but changed my seize the opportunity rather than just mind the day before joining (it’s a long focusing on the threat. In the UK and the story). I never thought about a career in Midlands, we’ve developed an aerospace supply management but my path crossed sector that we can be proud of and, with those of two great men who gave me the right level of attention and investment, the procurement bug! Their influence is can still grow. probably why I’m where I am today. Beyond globalisation, we need to consider the role that disruptive technology HOW IMPORTANT HAVE LANGUAGES BEEN IN or players can have in the future. Who YOUR CAREER? would have thought 10 years ago that the I’ve worked in seven or eight countries rising space players would come from over my career and I’ve always been PayPal and Amazon? fascinated by the breadth of knowledge you gain when immersed in a new culture. “[Globalisation] is inevitable. WHAT DO YOU SEE AS THE BIGGEST I only speak three languages (French, CHALLENGES FACING AEROSPACE SUPPLY English and Russian) but they’ve been very We need to embrace it CHAIN COMPANIES IN THE MIDLANDS? important at different stages of my career. and seize the opportunity To stay ahead of the curve and gain market Speaking Russian can be a lifesaver when share, our Midlands companies need to your plane is delayed and you arrive in the rather than just focusing address four areas: Ural region at 2am and the person who on the threat” ■ Productivity was supposed to welcome you is sleeping! ■ Supply Management ■ Factor and Capital Costs WHAT OTHER SKILLS DO YOU FIND USEFUL? I gained from working in these sectors. ■ Management Capabilities. In procurement, ‘soft’ skills are as You really have to understand and focus These were the opportunities for important as professional qualifications. on the needs/aim of the business/industry improvement I highlighted when I Effective procurement is the art of bringing before defining your procurement strategy. presented a side-by-side comparison your internal stakeholders and your The best practices in automotive may fail of the UK and German supply chain external suppliers to work together. This miserably in aerospace or nuclear. performance at the first MAA conference in requires a lot of influencing, relationship 2013. I think they’re still topical today. building and convincing. I’ve always WHAT INSPIRES YOU ABOUT AEROSPACE? found that in times of trouble, having I think the aerospace industry is unique. WHAT ARE YOU ABLE TO CONTRIBUTE the right level of engagement and good There are few sectors where your order AS A DIRECTOR OF THE MAA? relationships with your suppliers are more book is guaranteed for years and you don’t Having a unique position as a customer helpful than your contractual position. really need to worry about sales (this is and supply chain executive, I can advise on over-simplifying). From a procurement market trends, customers’ expectations WHAT HAVE YOU GAINED BY WORKING IN professional standpoint, what I like is the and procurement practices. I think this DIFFERENT INDUSTRIES? untapped potential that I can see compared helps the board make sure the MAA is One size does not fit all! I’ve worked in to other industries. There are so many cost supporting our members with a forward the nuclear, automotive, aerospace and and innovation opportunities around us look and a customer perspective. defence industries – all manufacturing that could benefit the entire supply chain but so diverse. Flexibility, adaptability if we can work them together. So my focus www.rolls-royce.com and forward-thinking are probably what right now is to make it happen.

14 MIDLANDS AEROSPACE FOR YOUR DIARY ONLINE: WWW.MIDLANDSAEROSPACE.ORG.UK/EVENTS NEW MEMBERS

The MAA welcomes the following new members

AEROSPACE CW FLETCHER MDXPRESS CAPABILITY PROJECT Sheffield Shenstone, Lichfield Derby Manufacture of precision Just-in-time express Accelerated business engineered components. delivery throughout growth technical the EU. support. EXTRUDE HONE Milton Keynes NDT MIDLANDS ALMOR GROUP Surface finishing Willenhall Nottingham for aero engine Non-destructive testing. Specialist alloy components. fabrication and furnace NEW TECHNOLOGY engineering. GOBEL & PARTNER CADCAM Birmingham Bromsgrove AON RISK SOLUTIONS Quality service in the Engineering software. Birmingham supply chain. Insurance/re-insurance RIGHTON AEROSPACE and risk management. HYDRO SYSTEMS UK Birmingham Derby Stock and distribution of THE AUTINS GROUP Design and manufacture raw materials. Rugby of tooling and Acoustic (NVH) and equipment. SUMMIT ENGINEERING thermal insulation (BIRMINGHAM) solutions. KIWA UK Solihull Cheltenham Precision machined CDI DOCUMENT Testing, inspection and components. MANAGEMENT certification. Walsall WH TILDESLEY

Organised by: Endorsed by: In partnership with: In association with: Document management. LANCASTER ALLOYS (FORGING) Worcester Willenhall CORPORATE Manufacture and supply Supply of forgings. TRAVELLER of weld wire filler Birmingham materials. WRIGHT HASSALL Travel management. Leamington Spa LOUGHBOROUGH Aerospace and advanced ABOUT THE MAA… COVENTRY UNIVERSITY manufacturing legal The Midlands Aerospace UNIVERSITY Loughborough support. Alliance (MAA) is the voice Coventry Research, teaching and of companies in the British Higher education and industrial collaboration. Midlands supplying global research. aerospace. Its 300 member organisations range from global aerospace players Become a member of the MAA and join the 300+ other to SMEs. The MAA board companies and organisations who are already enjoying the comprises senior managers benefits of belonging to one of Europe’s largest aerospace from Meggitt, Moog Aircraft industry trade groups. It costs your company only £495 per Group, Rolls-Royce and UTAS supply chain representatives year if you are in the Midlands or £690 if not. Actuation Systems, elected and key regional partner bodies.

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