Which material grades do you recommend for flight-weight, high-temperature housings?

We typically recommend Aluminum 7075-T6 or Titanium Ti-6Al-4V for standard high-strength aerospace applications. For extreme thermal operating environments near the exhaust or turbine sections, we utilize specialized magnesium alloys or Inconel superalloys.

Gearbox Housing

Frigate delivers precision-engineered aerospace gearbox housings designed to withstand extreme thermal and mechanical stresses in flight-critical applications. Utilizing advanced CNC machining and lightweight, high-strength alloys, we provide AS9100-quality manufacturing solutions tailored to exact aerospace specifications.

Material Grades

Aluminum 7075-T6, Titanium Ti-6Al-4V, Magnesium AZ91D, Inconel 718

Dimensional Tolerance

Down to ± 0.005 mm (± 0.0002 inches)

Geometric Tolerances (GD&T)

True position, cylindricity, and concentricity within 0.01 mm

Surface Roughness

Ra 0.4 μm (16 μin) as-machined; down to Ra 0.1 microns post-grinding

Weight Reduction

Lightweighting via advanced topology optimization and thin-walled ribbing

Order Type

Quantity Range

Lead Time*

First Article / Samples

1 – 5 Units

4 – 6 Weeks

Low-Volume Production

6 – 25 Units

8 – 10 Weeks

Medium-Volume Batching

26 – 100 Units

12 – 14 Weeks

Blanket Scheduled Orders

100+ Units (Annual)

Cyclic Release (JIT delivery)

*Delivery timelines are indicative and based on material availability. Exact schedules depend on geometry complexity, tooling requirements, and NDT queues.

Product Description

Frigate’s aerospace gearbox housings are critical structural enclosures engineered to protect gear trains and optimize power transmission in auxiliary power units, turbofans, and rotorcraft propulsion systems. Manufactured from premium, flight-certified cast or forged blocks, these housings feature exceptional strength-to-weight ratios and integrated cooling channels for superior heat dissipation.

Maximum Component Footprint

Up to 1200 x 1000 x 800 mm multi-axis machining envelope

Wall Thickness Minimum

Standard minimum wall thickness of 1.5 mm for critical flight-weighting

Machining Capabilities

Simultaneous 5-axis CNC milling, high-precision boring, and turn-mill centers

Nondestructive Testing (NDT)

ASTM-certified Liquid Penetrant (LPI) and Magnetic Particle Testing (MPI)

Internal Integrity Verification

Digital X-ray radiography and Computed Tomography (CT) scanning options

Surface Treatment & Finishing

Chromate conversion coating (MIL-DTL-5541), Anodizing (Type II/III), Primer

Thread & Insert Specifications

Helical wire inserts (Helicoils) installed to NASM/MS standards

CMM Inspection Accuracy

Coordinate Measuring Machine validation with volumetric accuracy of 1.5 μm

Sealing Surface Flatness

Flatness tolerance within 0.02 mm to ensure leak-proof mating interfaces

Quality Certifications

Fully compliant with AS9100 Rev D, ISO 9001:2015, and Nadcap processes

Technical Advantages

Our housings feature highly optimized structural ribbing developed through Finite Element Analysis (FEA) to eliminate unnecessary mass while maintaining absolute rigidity under torsional flight loads. Additionally, Frigate’s strict adherence to tight geometric tolerances guarantees flawless bearing alignment, drastically reducing vibration, drivetrain wear, and Total Cost of Ownership (TCO).

Let's Get Started

Need reliable Enclosure for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Commercial Aviation Propulsion

Main engine accessory gearboxes for commercial airliners requiring high thermal stability and precise bearing seat alignments under continuous flight hours.

Military Aircraft Drivetrains

Ruggedized rotorcraft and fighter jet gearbox casings built to endure extreme combat maneuvers, high g-forces, and rigorous shock-loading profiles.

Unmanned Aerial Vehicles (UAVs)

Ultra-lightweight micro-gearbox enclosures designed for long-endurance surveillance drones, optimizing every gram to maximize airborne mission range.

Auxiliary Power Units (APUs)

Compact, heat-resistant enclosures supporting high-speed turbine shafts, ensuring reliable power generation even during high-altitude operations.

Space Launch Vehicles

Actuator and turbopump gearbox structures manufactured to withstand severe cryogenic launch environments, intense acoustic vibrations, and vacuum conditions.

Urban Air Mobility (UAM / eVTOL)

Precision enclosures for electric propulsion units, designed for low-noise signatures, strict weight budgets, and rapid production scaling.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

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Having Doubts? Our FAQ

How does Frigate guarantee internal casting or forging integrity before final machining?

Every raw block or near-net-shape casting undergoes extensive non-destructive testing (NDT), including ultrasonic testing and digital X-ray inspection. This ensures that no subsurface porosity, inclusions, or micro-cracks compromise the structural integrity of the housing.

Can Frigate accommodate custom geometric dimensioning and tolerancing (GD&T)?

Yes, our engineering and production teams work directly from your 3D CAD models and 2D engineering drawings. We routinely execute tight GD&T requirements, such as true position and flatness tolerances down to 0.01 mm for critical mating faces.

Do you provide AS9100 First Article Inspection Reports (FAIR)?

Absolutely. All initial production and prototype batches are delivered with full AS9100 Rev D documentation, including AS9102 First Article Inspection Reports, material test certificates, heat treatment charts, and CMM dimension logs.

What surface finishes are applied to prevent galvanic corrosion in aerospace environments?

We offer a full suite of Nadcap-compliant surface treatments, including Type Chemical Conversion coatings, hard-coat anodizing, and specialized aerospace primers/topcoats. These treatments protect the housing from environmental moisture, hydraulic fluids, and galvanic action when mated with steel components.

We'd love to Manufacture for you!

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Components Built for Critical Performance

Engineered Products for Critical Applications

Gearbox Housing

Order Type

Quantity Range

Lead Time*

Product Description

Maximum Component Footprint

Wall Thickness Minimum

Machining Capabilities

Nondestructive Testing (NDT)

Internal Integrity Verification

Surface Treatment & Finishing

Thread & Insert Specifications

CMM Inspection Accuracy

Sealing Surface Flatness

Quality Certifications

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Gearbox Housing

Get Latest Price

Gearbox Housing

Get Latest Price