Aero Structures

Amphenol CIT has extensive manufacturing facilities for Aero Structures of all shapes and sizes. Manufacturing facilities in Franklin Wisconsin and Coventry UK, have capabilities to work in a wide variety of aerospace metals including aluminum, stainless steel, titanium, and select composites. Sheet metal, 3- and 5-axis CNC, lathe, long bed machining, water jet, 3D printing, as well as in house finishing make turning your designs into high-quality pedigreed aircraft parts quick and easy.  Manufacturing facilities are FAA PMA and EASA POA approved allowing parts to be delivered with airworthiness tags if requested. All parts receive AS9102 FAI and detailed inspection by an expert quality staff using the latest technology. Contact us today to discuss how Amphenol CIT can support your Aero Structures manufacturing from raw material all the way to flight-ready finished assembly.

Sheet Metal Stamping

Trumpf TruPunch CNC Punch/Shear Presses

  • Stamping sheet size – 4’x 6’-8”
  • Tolerance +/-.002” (.05 mm).
  • Materials typically stamped are  Aluminum, Acrylics, Teflon, Stainless Steels
  • Max thickness 1/4” Alu.  3/16” S.S
  • Full range of punch tooling numbering nearly 1,000 tool sets
  • Special tooling for the new punch press include
  • Flexible marking
  • Roller forming & deburring
  • Knockouts and half shearing
  • Flanging and Louver
  • Embossing and Engraving
  • Cupping
  • Fastener extrusions
  • Multi-bend

Sheet Metal Forming

Trumpf 90 Ton CNC Break Presses

  • Computer controlled 6 Axis back gages
  • Forming length range - .010”- 8’
  • Tight tolerance control within +/-.005” (.13 mm). Typical tolerance control within +/- .010”  (.025mm)
  • Angular tolerance control of +/- .5°
  • Materials typically formed are Aluminum series 2024, 5052, 6061 &7075, Stainless Steels,  and Copper
  • Full range of radius tooling from .015”- .500”
  • Fully robotic handling for high volume products

5-Axis Machining

DMG DMU 60 eVo 5-Axis Linear

The DMU 60 eVo combines the flexibility of modern universal milling machines with the performance potential of vertical machining centers. The NC swivel rotary table offers 5-axis simultaneous machining for exceptional surface quality while also expanding your application possibilities with complete machining of single parts or in serial production runs.

  • 23” x 19” x 19” working area
  • 882 lb maximum workpiece
  • High speed linear positioning
  • Best in class accuracy and flexibility

DMG DMC 100 duoBLOCK 5-Axis

The DMG duoBLOCK 5-axis machines set the benchmark for maximum precision, performance and efficiency and are engineered specifically for cutting the challenging alloys used in aerospace.

  • ø39” x 43” working area
  • ø31” x 39” table dimensions
  • 4,409 lb maximum workpiece
  • Linear positioning accuracy 4 µ
  • Rotational positioning accuracy 5 as
  • Linear straightness/flatness 4 µ
  • Volumetric accuracy 15 µ

DMG DMC 160U duoBLOCK 5-Axis

Large parts demand large working platforms and maximum productivity.  The DMC 160U offers a larger work platform without sacrificing any performance.

  • ø63” x 43” working area
  • ø49” x 39” table dimensions
  • 8,818 lb maximum workpiece
  • Linear positioning accuracy 4 µ
  • Rotational positioning accuracy 5 as
  • Linear straightness/flatness 6 µ
  • Volumetric accuracy 20 µ

Fooke Endura 7000LINEAR 5-Axis Gantry

Due to its high-dynamic features, the ENDURA is particularly suitable for the high-efficiency machining of ruled geometries, cutting contours, pockets, surfaces, drill holes, threads and spindle operations. Offering the highest dynamics in its class, from roughing to high precision processing it achieves excellent surface results and  dimensional accuracy.

  • 7’ x 11’ working area
  • Positioning accuracy of 0.0006 inch
  • Repeatability of 0.0004 inch

5-Axis Long Bed Machining

CMS Poseidon Double 5-Axis Gantry

For parts much too big for lesser equipment, the CMS Poseidon offers a vast working area capable of handling long bed machining needs in aluminums or composites.  Aircraft structural elements such as floor beams, frames, and stanchions are handled with ease using the dual 5-axis heads which can work in tandem or independently to maximize throughput.

  • 8’ x 26’ working area
  • Configurable for Single or Dual use

Water Jet Cutting

WARDJet ZXL-2043

The Z-2043 offers a high versatility water jet cutting solution which can accommodate sheets up to 12' in a wide variety of materials, including sheet metal, composites, foams, and more. This provides an attractive alternative to roughing operations using conventional machining centers and the ability to cut soft materials not suitable for conventional machining.

  • 6’ x 12’ working area
  • Positioning accuracy of 0.003"
  • Repeatability of 0.001"

Aluminum Finishing

MIL-DTL-5541 Automated Chemical Conversion Coating Line

  • Class 3 and Class 1A Finishing
  • RoHS Compliant Type II Process (Cr III)
  • Part handling up to 8’ x 5’ x 1.5’ thick
  • Max part handling weight of 250 lbs
  • Fully automated process chemistry monitoring and time in tank controls
  • Qualified on 2000, 5000, 6000, and 7000 series aluminum alloys


Priming and Top Coat Painting

  • 24’ x 14’ x 10’ paint booth
  • MIL Spec or Custom Paint Applications
  • Masking and Surface Preparation
  • Configurable Curing Ovens

Structured Assembly

Structure Assembly and Kitting

  • 100’s or 1,000’s of piece parts
  • Riveting
  • Hi-lok and specialty fasteners
  • Welding
  • Adhesive bonding
  • Press fit, crimp or swaged assembly
  • Packaging optimized for next level integration

Full Module Integration

Electro-mechanical Integration of Modules

  • Metal and Composite Structures
  • Discrete wiring, 10 GB data, optical fiber
  • Plenums and ductwork
  • Illuminated switch panels

More Information

To inquire about Aero Structures available from Amphenol CIT, please fill out the form below, and one of our Sales Engineers will contact you.

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