Engine mounts, chassis parts, and machined components for assembly lines.
Thrust reverser latches, bolt carrier assemblies, and fasteners for aircraft and defense sector.
Connector housings, EMI shielding brackets and lightweight chassis for industrial electronics parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Orthopedic implant screws, surgical drill guides and enclosures for sterile environments.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Rudders, propellers and corrosion-resistant components for offshore and deck-side systems.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Optimized for mass production, high-volume machining utilizes advanced automation and process control to ensure consistent quality, tight tolerances, and superior cost efficiency at scale.
Designed for precision-driven applications, low-volume machining supports prototype development and limited production runs with high accuracy, rapid iteration, and reduced tooling requirements.
To meet these requirements, machined surfaces are datum-aligned to reference planes with flatness and perpendicularity tolerances within ±10 μm. This high geometric fidelity prevents torsional asymmetry in the assembled configuration and ensures efficient load transfer under multi-axial conditions, in compliance with CS-25.301 and MIL-A-8865 standards.
Aircraft experience high-frequency, variable-amplitude loading throughout service life, leading to potential fatigue crack initiation at stress concentrators. Wing spar brackets are subjected to fatigue spectrum testing using flight-derived sequences such as TWIST, MiniTWIST, and FALSTAFF to qualify performance above 10⁸ cycles. Materials are selected based on their ΔK threshold behavior and resistance to microstructural shear banding. Shot peening and stress relief heat treatments are applied to eliminate residual tensile stresses from machining, thus extending fatigue life under fretting and vibratory load regimes.
Differential thermal expansion between bracket alloys and mating structures can induce out-of-plane warping during flight temperature fluctuations. Finite Element thermal distortion simulations are validated using strain gauge instrumentation during controlled thermal cycles. Residual stress mapping through X-ray diffraction (XRD) ensures that post-machining distortion does not exceed 25 μm over the part length. Final stabilization is achieved through low-temperature aging processes and controlled cooling profiles during quench to maintain phase stability in 7000-series or Ti-6Al-4V brackets.
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Supports primary load transfer between front/rear spars and fuselage frames under bending, torsion, and axial compression during flight.
Connects carbon-fiber spars to composite fuselage nodes, maintaining alignment under dynamic aeroelastic loading and thermal gradients at altitude.
Transfers high-magnitude shear and bending loads from cantilevered wings to fuselage side members under extreme maneuver and cargo conditions.
Ensures dimensional stability and fatigue resistance at the wing interface, especially where fuselage curvature affects bracket alignment.
Withstands elevated thermal gradients and vibration amplitudes across titanium spars subjected to Mach-induced pressure and temperature transients.
Links secondary spars to rib webs and skin panels in outer wing zones with low deflection tolerances and variable load paths.
Load-bearing capacity is influenced by hole quality, surface integrity, and edge margin compliance. All bolt holes are precision reamed post-heat-treatment to maintain H7 tolerances and true position within 0.05 mm of nominal, minimizing localized stress risers. Interference fit holes for Hi-Lok, taper-lok, or interference-fit bolts are monitored for radial expansion and micro-yielding behavior.
Bracket installations in wingbox zones encounter galvanic coupling with aluminum spars, titanium skins, and steel fasteners. Electrochemical compatibility is engineered using MIL-DTL-5541 chromate conversion, Type II anodizing, or sol-gel treatments in conjunction with primer coatings. Salt fog exposure and alternate immersion tests (ASTM B117 and G44) are conducted to verify surface integrity after 1,000+ hours in humidity chambers.
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Frigate uses multi-axis CNC machining with thermal drift compensation and active tool wear monitoring for every production cycle. Statistical Process Control (SPC) is applied to all critical features with CpK >1.67 maintained. Coordinate Measuring Machines (CMMs) with volumetric calibration are used for batch-to-batch consistency. This process ensures zero part-to-part deviation in wingbox assembly lines.
Frigate performs ultrasonic testing (UT) per AMS-STD-2154 and applies frequency-optimized probes for titanium and aluminum alloys. This allows detection of voids, laminations, and micro-inclusions prior to machining. High-risk zones are further verified using phased array UT or digital radiography. Each bracket includes UT traceability in the quality documentation.
All fastener holes are final-reamed post heat-treatment using precision boring to maintain H7 tolerances and concentricity within 0.05 mm. Frigate uses air gauging and optical metrology to validate roundness and alignment across bolt stacks. This prevents joint imbalance during torque application. Compliance is documented to NAS640 and ASME Y14.5 standards.
Frigate uses low-stress roughing strategies and symmetric machining sequences to minimize residual stress buildup. Intermediate stress relief treatments are applied during multi-stage machining of thick-section brackets. Final stabilization is performed using controlled aging cycles. Distortion is measured and corrected using precision fixturing and iterative laser scanning.
Frigate selects coatings based on potential difference between bracket alloy and mating structure. Alodine 1200, Type II anodizing, and sol-gel primers are applied based on aircraft program specifications. Surface resistivity and film thickness are verified using ASTM B449 and MIL-DTL-81706 procedures. This ensures long-term corrosion resistance under condensate exposure in wingbox environments.
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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!