In the demanding world of aviation, OEMs face constant pressure to innovate, maintain quality, and control costs. Increasingly, they are finding a valuable partner in job shop operations like what we have in Duncan Manufacturing Solutions, or DMS. DMS was started to support Duncan Aviation’s internal needs while providing service to business aircraft owners and operators. However, DMS is rapidly expanding to offer compelling solutions to aviation OEMs and other industries with complex fabrication requirements.
These solutions are critical for OEMs seeking specialized expertise, flexibility, cost-effectiveness, and a commitment to quality. By partnering with DMS, OEMs can streamline their fabrication processes, maintain operational efficiency, and focus on their core strengths, ultimately driving innovation and success.
DMS, with 40 years of experience and FAA PMA (Parts Manufacturing Approval) authorization, brings a wealth of expertise to the table. This is particularly crucial in aviation, where stringent regulations and complex materials demand specialized knowledge. The ability to fabricate anything from support structures to interior aesthetic components demonstrates the versatility of DMS.
DMS is committed to innovation and problem- solving. This proactive approach is invaluable, especially when dealing with aging aircraft requiring out-of-production parts. DMS can handle projects from prototype to finished assembly, complete with customer data. This flexibility and customization extends beyond aging aircraft, assisting OEMs in creating unique, custom parts for new projects.
When outsourcing to job shop operations, OEMs avoid the significant capital investment associated with establishing and maintaining fabrication capabilities. This, along with the ability to provide faster turnaround times, helps OEMs meet tight deadlines and manage budgets.
DMS holds both AS 9100D and ISO 9001:2015 certifications. These certifications are the international standard for Quality Management Systems for aviation manufacturing organizations. They dictate system requirements with the challenges of the aviation industry
in mind and are required for government and aviation parts manufacturing support contracts. The scope of these certifications are for sheet metal, composite, and precision-machined components, as well as specialized processes like welding and finishing, which allows DMS to meet the requirements of government and aviation parts manufacturing support contracts.
Gogo, a leader in inflight connectivity and entertainment systems, turned to DMS as a resource to build the Gogo AVANCE L5 Broadband Internet and Wi-Fi kits. These kits support Duncan Aviation- developed STCs and installation packages for the following business aircraft models, showcasing our ability to support complex, integrated systems:
Nearly all the advanced manufacturing equipment and capabilities in DMS were put to use fabricating the kits to support Gogo.
CNC milling was used to create the contour plates for all model kits, often requiring multiple passes for parts with intricate specifications.
Haas VF5, Haas VF6, and Haas UMC750 Five- Axis mills, along with an Epilog Fusion Pro 48 Dual Laser Engraver and a Haas ST-30Y Lathe, allow for the precise machining of complex parts.
All flat sheet metal components of varying thicknesses were cut using an Omax 60120 Waterjet, while an Accurpress 7606 Press Brake forms sheet metal into desired shapes and angles.
For the Gogo AVANCE L5 kits, DMS bonds the components to the aircraft belly with composite materials, reinforcing the antenna’s installations. A state-of-the-art, positive airflow composite shop, complete with a clean room and paint booth, supports prepreg composite repairs and manufacturing.
A Stratasys Fortus 450MC 3D Printer is used to create tooling and drill fixtures to ensure accuracy when drilling panel holes for mounting contour plates and doublers. It is also used to create a mold for the press form beams for the CL300/CL350 kits.
A John Shaw Rubber Pad Press, utilizing molds printed with the 3D printer, press forms beams for the Gogo CL300/CL350 kits.
These aluminum parts are pressed in O condition, allowing for complex shapes and geometries. They are then heat-treated to final temperature.
Two Delta H Heat Treat Ovens provide ample capacity for heat-treating components like the press form beams for the Gogo CL300/CL350 kits, ensuring maximum strength through controlled tempering, conductivity, and rock hardness testing.
With the use of precision equipment like the Zeiss Contura 12/18/10 Coordinate Measuring Machine with Vast XXT TL3 articulating sensor for multi- axis measurements, DMS ensures part accuracy, like the complex contoured parts associated with Gogo kit installs.
From prototype to production, DMS excels in job shop work, delivering high-quality precision parts tailored to complex specifications.
DMS is more than just a parts fabricator. We are a partner, building reciprocal relationships with customers and vendors alike. Whether the need is for a single part or a large production run, DMS is equipped to handle the challenge with a focus on quality, precision, and collaborative problem- solving. Our commitment to the aviation industry, combined with versatile capabilities, positions DMS as a unique and valuable resource for OEMs across various sectors.
Learn more about Duncan Aviation's manufacturing capabilities.