Our Services
Piece by piece top quality
When it comes to manufacturing high-precision aircraft parts, Kaelin is your partner. Whether single parts or entire assemblies - we manufacture technically sophisticated and efficient components of the highest precision and functionality. We work according to design data, sample components and drawings and produce 3D scans of existing components, on the basis of which we create the necessary production drawings if required. In order to achieve the desired production quality, we use numerous aviation-specific processes that enable us to achieve a high level of vertical integration in-house. These include hydroforming, integral milling and non-destructive material testing, for example. We also provide surface treatments such as painting or corrosion protection, manufacture welded aviation parts and perform heat treatments for aluminum and steel.
Precisely manufactured - we produce single parts or assemblies on state-of-the-art CNC systems
Quality that is visible in every detail
From the component to the perfect surface. Careful painting is part of our comprehensive manufacturing expertise
Reliably tested - non-destructive testing methods detect even the finest material defects and guarantee top quality
Connections that last. Certified aviation welding for the highest safety requirements
Our SurTec 650 treatment ensures reliable Corrosion protection and a conductive surface
Workflow
A passion for precision components -
the most important steps
- Performing precise and high-resolution 3D recordings of physical objects with different surfaces in difficult environments (e.g. insensitive to surface reflections on shiny surfaces)
- Continuous self-positioning through dynamic referencing
- Consistent and repeatable results under difficult working conditions and in all environments
- Portable
- Accuracy up to 0.025mm (can only be achieved under optimal conditions)
- Volumetric accuracy of 0.020 mm and 0.040 mm/m
- Wide scanning range from 0.05 - 8m
- Scan can be exported as a surface model for various CAD programs
- Measurements (e.g. inspection of first articles of aircraft parts, comparison of prototypes with existing CAD model, recording and evaluation of damage, etc.)
- Reverse engineering
- 3-axis portal milling machines (2 pieces)
- Solid carbide miling of the latest generation
- Component size 2050x1550x220mm
- Machining of small parts using hold-down devices
- HSC machining process with up to 32000 revolutions (9kw / 15kw high speeds = efficient work with small Miling cutters)
- Uncomplicated, fast and clean processing of a wide range of panel types from 0.2 mm to 200 mm material thickness
- Highly precise milling work
- Very short set-up times thanks to vacuum clamping systems
- Extremely modular, flexible, fast work possible as no major modifications are required (e.g. quick replacement of 0.3 mm sheet to 200 mm block)
- Manufacture of tool molds, aerospace milled parts and fixture components
- Contour milling
- 5-axis Hermle C22: 18,000 rpm spindle, optional high-speed spindles can be used: stepless up to 50,000 rpm, travel 450x600x330mm
- Oven is certified according to AMS 2750F
- Oven class 2
- Oven interior dimensions (LxWxH): 1500 mm x 2200 mm x 1200 mm
- Calibrated usable space (LxWxH): 1300 x 2000 x 1000 mm (area in which the temperature tolerance is maintained)
- Temperature range 150 degrees to 610 degrees Celsius
- Tolerance +/ - 6 degrees Celsius
- Heat treatment processes:
- Solution annealing of aluminium
- Stress relief annealing of steel
- Painting: Size of the paint booth (LxWxH): 8m x 4m x 2.7m
- Primers and top coats
- Corrosion protection treatment of surfaces and interiors
- Non-destructive testing:
- Dye penetration testing
- Conductivity testing
- Coating thickness measurement
- Eddy current and X-ray testing via partners
- 4 hydraulic presses
- Processing area (LxWxH): 6000 mm x 910 mm x 820 mm
- Pressing speed: 2.1 mm per second
- Maximum pressing force: 600 t
- Folding length 3m
- 110t pressing pressure
- Available radii 1, 2, 3, 4, 6, 7 mm
- Larger radii can be stepped
- CNC-controlled edging processes
- Edging based on step data or manually
- Maximum material thickness for edging: up to 2.5 mm
- Welder's certificate ISO 24394
- TIG welding process according to ISO 4063
- Material group A TP1-TP5
- Material group B and F TP2 and TP3
- Pipe diameters from 12 mm upwards
- Material thickness from 1.0 mm - 6.4 mm
- Tools & Tool Shapes:
- Hand riveting pliers
- Lance for applying corrosion protection fluid
- Riveting tools for pipe connections
- Positive and negative pressing dies
- Positive and negative forming tools (e.g. for crimping pipes)
- Jigs / Plant construction
- Assembly fixtures
- Gauge/workpiece holders
- Transport devices
Customer benefits
Four reasons for top quality
01
Kaelin has an immense wealth of experience in both classics and state-of-the-art aircraft structures from which the customer benefits.
02
Kaelin has a sophisticated machine and tool park. This means that 95% of all parts can be processed in-house.
03
The large network in the aviation industry enables Kaelin to continuously optimize and simplify manufactoring methods.
04
Innovative solutions in the creation of production data - efficient solutions in manufacture.