EAG Capabilities

EngineeringMachining, Moulding & CompositesSurface TreatmentsAssembly & Full Product BuildFabrication
CAD / CAMMulti-Axis CNC MachiningNDTElectro Mechanical AssemblyPunching & Forming
Rapid Proto-TypingWire / EDMPassivationElectro Mechanical TestLaser & Waterjet Cutting
Reverse EngineeringInjection Moulding & ThermoformingAnodisingClass 10K & 100K Clean RoomsPress & Rubber Braking
Collabrative EngineeringCompositesPaintingProcess ValidationWelding
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CNC Machining

Emerald Aero Group is a leading manufacturer of precision engineered aerospace components, offering capabilities in Multi-Axis CNC Milling and CNC Turning in a broad range of materials including; Aluminium, Stainless Steel, Steel, Titanium and Inconel.

Multi-Axis Machining

Surface Treatments

Emerald Aero Group provides a full process solution for component part manufacture including surface treatments.

NADCAP approved for:

NDT
Penetrant Flaw Detect, Hardness Testing, Conductivity Testing

Treatments
Alocrom, Chromic Anodising, Sulphuric Anodising, Chromic Passivation, Clear Passivation

Painting
Aerospace Paint Finishes Including: Primers, Top Coats and Dry Film Lubricants

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Fabrication

 

 

Emerald Aero Group has a comprehensive and substantial sheet metal manufacturing capability utilising a broad range of materials including: Titanium, Aluminium and Specialist Steels.

Capabilities Include:

  • Punching
  • Forming
  • Welding
  • Spot Welding
  • Tube & Pipe Forming
  • Stretch Forming
  • Pem Insertion
  • Grinding
  • Sanding
  • Laser Cutting
  • Waterjet Cutting
  • Routing
  • Brake Pressing
  • Rubber Pressing

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Composites

 

Since 2008 we have provided Composite; design, tooling, manufacturing and testing services to the aerospace sector.

We have the capability to manufacture primary structural parts up to 6m in length and maintain an aerospace-accredited manufacturing facility staffed by trained and qualified personnel.

Core equipment includes a 2.5m diameter x 6m long autoclave and a 250m² cleanroom.

The company also operates the following equipment:

  • 1.5m diameter x 3.0m long autoclave, 10 bar pressure, 400ºC.
  • 100 tonne double-daylight press, platen sizes 1.5 metre x 0.5 metre, 450ºC.
  • An infrared rapid heating system for press-forming of thermoplastic composites.
  • 80 tonne single-daylight press, platen sizes 1.0 metre x 1.0 metre, 200ºC.
  • Calibrated aerospace oven, 2.0m x 2.0m x 2.0m, 200ºC.
  • 0.6 metre diameter x 1.2 metre experimental autoclave, 20 bar pressure, 450ºC.
  • RTM machines – single and multi-part systems, pressure-pot system, up to 120ºC.
  • Refrigerated store – calibrated to aerospace standards.
  • Paint booth – calibrated to aerospace standards.
  • Grit blasting unit – calibrated to aerospace standards.
  • 1m² Midas NDT Ultrasonic C-scan.

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Injection Moulding

Emerald Aero Group offers Injection Moulding: design, tooling, proto-typing and manufacturing capabilities to the aerospace sector. Utilising advanced technologies to provide innovative competitive polymer solutions.

Customer solutions are supported by:

  • Design for Manufacture Processes
  • Full In-house CNC Integrated Tool-room with Design Mould Office
  • 37 Injection Moulding Machines ranging from 30 to 11 Ton
  • Automated Material Handling Systems
  • CMM Laboratory for Post Moulding Verification

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Thermoforming

 

 

Emerald Aero Group (EAG) provides thermoforming; design, tooling and manufacturing capabilities utilising a broad range of polymers. Our supply chain partners include: Kydex, Boltaron and Lexan.

We have the capability to manufacture components up to 1m in length and maintain an aerospace-accredited manufacturing facility staffed by trained and qualified personnel.

Manufacturing processes include:

  • Vacuum Forming,
  • Line Bending
  • 3 and 5 axis CNC Routing
  • Sub-assembly & Assembly

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3D Printing

Emerald Aero Group provides 3D Printing capabilities for: Concept Models, Functional Prototypes, Manufacturing Tools and End-Use Parts.

Services offered provide solutions for:

  • Rapid Prototyping, Concept Models, Iterative Design, Pilot Production
  • Production of Component Parts, Sub-assemblies and Assemblies
  • Production Simulation
  • Bridge-to-Production
  • Quick Turnaround Parts (No Minimum Batch Size)
  • Full Production/Manufacturing
  • End-of-life (Bridge)
  • Extend Product Life without Tooling
  • Spares & Repair Support

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