Aerospace CNC Machining Services
Aerospace CNC machining at FIRMFG produces precision flight-critical components in an AS9100D certified and ITAR registered facility. We machine titanium, Inconel, aluminum 7075, and exotic superalloys on 5-axis simultaneous machining centers to tolerances of ±0.005 mm. Full material traceability, NDT inspection, and First Article Inspection per AS9102 included with every order.
Aerospace CNC Machining Services: AS9100D Certified Precision Manufacturing
Aerospace CNC machining at FIRMFG delivers precision-manufactured components that meet the most demanding requirements in commercial aviation, defense, and space exploration. Operating under an AS9100D certified and ITAR registered quality management system, we machine exotic materials — including titanium Ti-6Al-4V, Inconel 718, Inconel 625, aluminum 7075-T6, aluminum 2024-T3, 17-4PH stainless steel, Hastelloy X, and Waspaloy — to tolerances as tight as ±0.005 mm on flight-critical features. Every part is backed by full material traceability, NDT inspection, and First Article Inspection (FAI) per AS9102.
Aerospace manufacturing operates at a fundamentally different level of control than general CNC machining. Every material lot must be certified to aerospace material specifications (AMS). Every machining process must be validated and locked. Every flight-critical feature must be 100% inspected — not sampled. And every part must carry a documentation chain that traces it from raw material mill certificate through machining records, NDT results, special process verification, and final inspection. FIRMFG's AS9100D system enforces these requirements on every aerospace order, whether it is a single prototype for design validation or a production batch of 500+ flight-critical components.
Our aerospace machining capabilities span the full spectrum of aircraft and spacecraft component manufacturing: turbine blades and impellers with complex airfoil profiles machined via simultaneous 5-axis, structural brackets and fittings in aluminum 7075-T6 with thin-wall features down to 0.8 mm, landing gear components in 300M steel and titanium with NDT inspection per AMS-STD-2154, avionics housings with EMI shielding features, hydraulic manifolds with precision-honed bores, fuel system parts with micro-drilled ports, satellite components in thermally stable alloys, and UAV structures optimized for maximum strength-to-weight ratio.
This guide covers everything you need to know about aerospace CNC machining — capabilities, exotic materials, 5-axis machining strategy, the AS9100D quality system, tolerances, surface treatments, NDT options, and the prototype-to-production journey. Use it as a reference when designing your next aerospace component, or skip ahead and request a quote for an immediate price, lead time, and DFM review.
Quick Specs: Aerospace CNC Machining
FIRMFG's aerospace CNC machining capabilities and quality certifications. These specifications apply to all aerospace, defense, and space component orders.
Aerospace Machining Capabilities
| Capability | Specification |
|---|---|
| Tightest Tolerance | ±0.005 mm (±5 μm) |
| Standard Tolerance | ±0.01 mm (±10 μm) |
| Surface Finish (Best) | Ra 0.2 μm |
| Surface Finish (Standard) | Ra 0.4 – 0.8 μm |
| Max Part Size | 1200 × 600 × 500 mm |
| Machining Axes | 5-Axis simultaneous |
| Min Feature Size | 0.05 mm (50 μm) |
| Positional Accuracy | ±0.008 mm |
| Max Spindle Speed | 42,000 RPM |
| Quality Standard | AS9100D Certified |
Quality Certifications & Compliance
| Certification | Scope | Status |
|---|---|---|
| AS9100D | Aerospace Quality Management System | Certified |
| ITAR Registered | International Traffic in Arms Regulations (USML defense articles) | Registered |
| ISO 9001:2015 | Quality Management System | Certified |
| Nadcap | Special Processes (Chemical Processing, NDT) | Compliant |
AS9100D certification covers the full aerospace quality management system including configuration management, risk management, counterfeit-parts prevention, and traceability. ITAR registration authorizes the manufacture of defense articles on the United States Munitions List (USML). Nadcap compliance covers chemical processing and non-destructive testing special processes.
Aerospace Parts We Machine
FIRMFG machines the full range of aerospace, defense, and space components — from turbine blades and structural fittings to landing gear and satellite mechanisms. Each part category is backed by validated processes, certified materials, and AS9100D documentation.
Turbine & Engine Components
Precision machining of turbine blades, impellers, blisks, vanes, and nozzle guide vanes in Inconel 718, Waspaloy, and titanium. 5-axis simultaneous machining of complex airfoil profiles with controlled surface finish to Ra 0.4 μm and profile tolerances of ±0.01 mm on critical leading and trailing edges.
Precision Requirements
Profile ±0.01 mm · Ra 0.4 μm · 5-axis simultaneous
Structural Parts
Aircraft structural brackets, ribs, spars, fittings, and mounts machined from aluminum 7075-T6 and titanium Ti-6Al-4V. Thin-wall features down to 0.8 mm with controlled warpage. Pocketing strategies optimized for maximum strength-to-weight ratio. Full material traceability and CMM inspection on all flight-critical dimensions.
Precision Requirements
Wall 0.8 mm · ±0.01 mm · Ra 0.8 μm
Landing Gear
Landing gear components including struts, axles, brackets, and actuator housings machined from 300M steel and titanium. High-stress components requiring tight bore tolerances (±0.005 mm), controlled surface finish (Ra 0.4 μm), and NDT inspection per AMS-STD-2154. Shot peening and chrome plating available for fatigue enhancement.
Precision Requirements
Bore ±0.005 mm · Ra 0.4 μm · NDT per AMS-STD-2154
Avionics Housings
Precision-machined enclosures and housings for avionics electronics, flight control computers, and navigation systems. Aluminum 6061-T6 and 7075-T6 housings with EMI shielding features, thermal management pockets, and controlled flatness on sealing surfaces (0.02 mm). Conformal coating and conductive gasket grooves machined to ±0.02 mm.
Precision Requirements
Flatness 0.02 mm · ±0.02 mm · EMI features
Hydraulic Components
Hydraulic manifolds, valve bodies, actuator cylinders, and pistons machined from stainless steel 17-4PH and titanium. Precision bores honed to Ra 0.2 μm with cylindricity to 0.003 mm. Cross-drilled intersecting ports sealed with aerospace fittings. Pressure-tested and NDT inspected for flight-critical hydraulic systems.
Precision Requirements
Bore Ra 0.2 μm · Cylindricity 0.003 mm · ±0.005 mm
Fuel System Parts
Fuel system components including pump housings, valve bodies, injector nozzles, and manifold blocks. Machined from aluminum 7075-T6, stainless steel, and titanium. Fuel-tight sealing surfaces with flatness to 0.01 mm. Micro-drilled fuel injector ports down to 0.2 mm diameter with controlled flow geometry.
Precision Requirements
Flatness 0.01 mm · Ports 0.2 mm · ±0.005 mm
Satellite Components
Satellite and spacecraft components including antenna mounts, optical benches, structural nodes, and deployment mechanisms. Ultra-low-outgassing materials (aluminum 6061-T6, titanium, Invar 36). Dimensional stability to ±0.005 mm in thermal cycling environments. Lightweight pocketing optimized for launch-load survival.
Precision Requirements
±0.005 mm · Thermal stable · Ra 0.4 μm
UAV Parts
Unmanned aerial vehicle components including airframe structures, rotor hubs, gimbal mounts, and payload enclosures. Lightweight aluminum 7075-T6 and carbon-fiber-compatible titanium fittings. Thin-wall machining to 0.5 mm for weight optimization. Rapid prototyping to production with AS9100D documentation.
Precision Requirements
Wall 0.5 mm · ±0.01 mm · Ra 0.8 μm
Aerospace Materials We Machine
Aerospace material selection is governed by AMS specifications, temperature requirements, strength-to-weight ratios, and fatigue life. FIRMFG machines the eight primary aerospace materials below, each with full mill certifications and AMS traceability.
Titanium Ti-6Al-4V (Grade 5)
Tensile 950 MPa · Density 4.43 g/cm³ · Elastic modulus 114 GPa · Service temp to 400°C
Ti-6Al-4V is the workhorse of aerospace structures. Its exceptional strength-to-weight ratio, corrosion resistance, and compatibility with composite airframes make it the dominant titanium alloy in both commercial and defense aircraft. Machinability is rated at approximately 40% relative to free-machining steel, demanding specialized tooling strategies.
Aerospace Application
Turbine blades, structural fittings, landing gear, fasteners, engine mounts
Machinability Rating
Challenging — low thermal conductivity causes heat buildup at cutting edge. Requires sharp carbide, low cutting speeds (30–60 m/min), high-pressure coolant, and rigid setups to prevent chatter.
Inconel 718
Tensile 1,240 MPa · Density 8.19 g/cm³ · Service temp to 700°C · Hardness 36 HRC (aged)
Inconel 718 is a precipitation-hardenable nickel-chromium superalloy engineered for the hottest sections of jet engines. It retains strength at 700°C where most metals would creep and fail. The alloy accounts for approximately 45% of the mass of modern aircraft engines. Its extreme machinability challenges — rapid tool wear, built-up edge, and thermal damage — require dedicated aerospace machining expertise.
Aerospace Application
Turbine disks, compressor blades, casings, rocket engine parts, exhaust systems
Machinability Rating
Very difficult — high work-hardening rate, high shear strength, and low thermal conductivity. Requires coated carbide or ceramic inserts, low speeds (15–30 m/min), and high-pressure coolant.
Inconel 625
Tensile 930 MPa · Density 8.44 g/cm³ · Service temp to 816°C · Excellent corrosion resistance
Inconel 625 is valued for its outstanding combination of high-temperature strength and exceptional resistance to oxidation, pitting, and crevice corrosion. It is widely used in aerospace exhaust and ducting systems where both heat and corrosive gases are present. Unlike Inconel 718, it is solid-solution strengthened and does not require precipitation hardening.
Aerospace Application
Exhaust systems, ducting, fuel lines, heat shields, turbine shrouds
Machinability Rating
Difficult — similar to Inconel 718 with slightly better chip breaking. Requires positive-rake carbide, rigid fixturing, and abundant coolant to manage thermal load.
Aluminum 7075-T6
Tensile 572 MPa · Yield 503 MPa · Density 2.81 g/cm³ · Hardness 150 HB
Aluminum 7075-T6 is the primary high-strength aluminum alloy in aerospace structures. Its zinc-magnesium-copper precipitation hardening delivers the highest strength-to-weight ratio of any structural aluminum. Used extensively in commercial and military aircraft where weight reduction is critical. Stress-corrosion cracking susceptibility limits its use in corrosive environments without protective finishing.
Aerospace Application
Aircraft structural members, fuselage frames, wing ribs, bulkheads, UAV frames
Machinability Rating
Good — machinability rating approximately 80% of 6061. Sharp carbide, moderate speeds (300–500 m/min), and flood coolant produce excellent surface finish and dimensional accuracy.
Aluminum 2024-T3
Tensile 483 MPa · Yield 345 MPa · Density 2.78 g/cm³ · Excellent fatigue resistance
Aluminum 2024-T3 is the standard alloy for fatigue-critical aircraft structures, particularly in wing and fuselage tension zones. Its copper-alloy composition provides superior fatigue life compared to 7075, though at lower overall strength. Cladding with pure aluminum (Alclad) provides corrosion protection for skin applications.
Aerospace Application
Wing tension zones, fuselage skin, structural panels, high-stress brackets
Machinability Rating
Good — similar to 7075 with slightly softer chips. Polished carbide with positive geometry and flood coolant prevents built-up edge formation.
Stainless 17-4PH
Tensile 1,070 MPa (H1025) · Hardness 38 HRC · Heat-treatable · Good corrosion resistance
17-4PH is a martensitic precipitation-hardening stainless steel combining high strength, good toughness, and excellent corrosion resistance. In aerospace, it is specified for hydraulic system components and structural fittings that require both strength and corrosion protection. The ability to machine in the annealed state and then heat-treat to final hardness (H900–H1150) simplifies manufacturing of complex geometries.
Aerospace Application
Landing gear actuators, hydraulic valve bodies, pump shafts, structural fittings
Machinability Rating
Moderate — machined in solution-annealed Condition A, then precipitation hardened. Carbide tooling with moderate speeds (90–150 m/min) and rigid setups produce good results.
Hastelloy X
Tensile 790 MPa · Density 8.22 g/cm³ · Service temp to 1,200°C · Outstanding oxidation resistance
Hastelloy X is a nickel-chromium-iron-molybdenum superalloy designed for the most extreme thermal environments in gas turbine engines. It maintains structural integrity at temperatures exceeding 1,100°C and resists oxidizing and carburizing atmospheres. Used in combustion chambers and exhaust components where conventional alloys would fail rapidly.
Aerospace Application
Combustion chamber liners, turbine transition ducts, afterburner components
Machinability Rating
Very difficult — high strain-hardening, gummy chips, and rapid tool wear. Requires ceramic or CBN inserts, very low speeds, and high-pressure coolant strategies.
Waspaloy
Tensile 1,275 MPa · Density 8.19 g/cm³ · Service temp to 760°C · High creep resistance
Waspaloy is an age-hardenable nickel-base superalloy offering superior creep resistance at temperatures up to 760°C. It is specified for the most demanding turbine disk and blade applications where Inconel 718 reaches its thermal limits. Its extreme machining difficulty makes it one of the highest-cost aerospace materials to process, requiring specialized expertise and equipment.
Aerospace Application
Turbine disks, high-temperature fasteners, compressor blades, seals
Machinability Rating
Extremely difficult — one of the most challenging aerospace alloys. Requires advanced coated carbide or ceramic inserts, very low cutting speeds, and rigid machine tools with high spindle torque.
5-Axis CNC Machining for Complex Aerospace Geometries
5-axis simultaneous machining is not optional for aerospace — it is essential. Turbine blades, impellers, blisks, and structural nodes cannot be produced to aerospace tolerances on 3-axis or 4-axis equipment. FIRMFG's 5-axis capability eliminates re-fixturing, reduces tolerance stackup, and enables single-setup machining of the most complex aerospace geometries.
Why 5-Axis Is Critical for Aerospace
Aerospace components are defined by complex 3D surfaces — airfoil profiles on turbine blades, curved impeller vanes, compound-angle structural features, and organic-load-optimized geometries. These cannot be machined by indexing the part between discrete 3-axis operations because each re-fixturing introduces tolerance stackup of ±0.02–0.05 mm, which exceeds the ±0.005 mm budget for flight-critical features.
Simultaneous 5-axis machining tilts and rotates the cutting tool continuously as it moves along the X, Y, and Z axes, maintaining optimal tool contact angle throughout the toolpath. This enables machining of undercuts, steep walls, and complex curves in a single setup — reducing tolerance accumulation, improving surface finish, and dramatically reducing cycle time on complex parts.
5-Axis Capabilities
FIRMFG operates simultaneous 5-axis machining centers with trunnion-table and swivel-head configurations. Rotary table specifications include ±0.008 mm positional accuracy and 0.005 mm repeatability on B and C rotary axes. Maximum part envelope is 1,200 × 600 × 500 mm with rotary clearance for parts up to 400 mm diameter.
Advanced CAM strategies — including trochoidal milling, adaptive roughing, and 3+2 positioning for deep features — are applied based on geometry and material. For Inconel and titanium, we use high-torque spindles with through-tool high-pressure coolant (70 bar) to manage thermal load and chip evacuation. In-process probing verifies feature locations between operations, compensating for thermal growth and tool wear on long-running aerospace parts.
3-Axis vs 4-Axis vs 5-Axis for Aerospace Parts
| Configuration | Aerospace Suitability | Typical Parts | Setups | Tolerance Stackup | Notes |
|---|---|---|---|---|---|
| 3-Axis | Limited | Flat brackets, plates, simple housings | 2–4 | ±0.02 – 0.05 mm | Multiple re-fixturings accumulate tolerance error |
| 4-Axis | Moderate | Cylindrical parts, cams, blade platforms | 1–2 | ±0.01 – 0.02 mm | Rotary indexing reduces setups on angled features |
| 5-Axis | Essential | Turbine blades, impellers, blisks, structural nodes | 1 | ±0.005 – 0.01 mm | Single-setup machining eliminates re-fixturing error |
Aerospace Quality System
Aerospace CNC machining requires a quality management system that goes far beyond ISO 9001. FIRMFG operates under AS9100D, ITAR registration, and Nadcap-compliant special processes — with full traceability from raw material mill certificate to final inspected and packaged component.
AS9100D Process Overview
AS9100D is the international quality management standard for aviation, space, and defense organizations. It builds on ISO 9001 with aerospace-specific requirements for configuration management, risk management, counterfeit-parts prevention, product safety, and ethical behavior. Our AS9100D system governs every aspect of aerospace part production — from DFM review and material sourcing through machining, inspection, NDT, and shipping.
Key AS9100D requirements include: documented risk assessments on every new part number, configuration-controlled drawings and work instructions, FOD (Foreign Object Debris) prevention procedures, calibration of all inspection equipment to NIST-traceable standards, and a formal corrective action system (CAPA) for any nonconformance. Critical processes — including machining of flight-critical features, NDT, and surface treatment — are validated rather than merely verified.
ITAR Compliance: What It Means
ITAR (International Traffic in Arms Regulations) is a U.S. regulatory framework governing the manufacture, export, and brokering of defense articles and services listed on the United States Munitions List (USML). FIRMFG is ITAR registered, meaning we are authorized to manufacture defense-related aerospace components including military aircraft parts, missile components, and space defense hardware.
For customers, ITAR compliance means: all technical data (drawings, CAD models, specifications) is handled under controlled access with restricted personnel; manufacturing occurs in a secured facility with access controls; export of technical data or defense articles requires proper licensing; and all records are retained per ITAR retention requirements. This compliance framework ensures that defense-related aerospace work is handled with the legal and security rigor required by U.S. law.
Full Material Traceability
Full traceability is the backbone of aerospace manufacturing. Every part FIRMFG produces carries a four-link documentation chain that enables forward and backward traceability from raw material mill certificate to final inspected and packaged component:
Mill Certificate
Certified Material Test Report (CMTR) with heat number, chemistry, mechanical properties, and AMS specification. Linked to incoming material lot.
Machining Record
Process parameters, machine ID, operator, tool changes, and in-process inspection data for every operation in the routing.
Inspection & NDT
CMM, optical, surface measurement, and NDT results (FPI, X-ray, ultrasonic). 100% verification on flight-critical features.
Special Process & Shipping
Shot peening, anodizing, passivation records. Final inspection, packaging, and quality record package compiled per AS9100D.
Non-Destructive Testing (NDT) Options
Aerospace components — particularly flight-critical parts — require NDT to verify the absence of surface or subsurface defects that could lead to in-service failure. FIRMFG provides the following NDT options, all performed by certified technicians per applicable aerospace standards:
- FPI (Fluorescent Penetrant Inspection) — detects surface-breaking cracks, porosity, and laps per AMS 2644 / ASTM E1417
- X-Ray Inspection — detects internal defects, porosity, and inclusions per ASTM E1742
- Ultrasonic Testing — detects subsurface flaws and measures wall thickness per AMS-STD-2154
Tolerances for Aerospace Parts
Aerospace components demand tolerances measured in single-digit micrometers. Turbine blade profiles, mating surfaces, gear teeth, and seal grooves each have specific precision requirements that FIRMFG achieves through validated processes, 5-axis machining, and 100% inspection on flight-critical features.
| Feature | Standard (±) | Precision (±) | Flight-Critical (±) |
|---|---|---|---|
| Turbine Blade Profile | ±0.025 mm | ±0.010 mm | ±0.005 mm |
| Mating Surfaces (Sealing) | ±0.020 mm | ±0.008 mm | ±0.003 mm |
| Gear Teeth (Pitch) | ±0.030 mm | ±0.010 mm | ±0.005 mm |
| Seal Grooves | ±0.020 mm | ±0.008 mm | ±0.004 mm |
| Bushing Bores | ±0.015 mm | ±0.005 mm | ±0.002 mm |
| Bolt Hole Patterns (Position) | Ø0.05 mm | Ø0.02 mm | Ø0.01 mm |
| Thin-Wall Features | ±0.030 mm | ±0.015 mm | ±0.008 mm |
| Positional Accuracy (5-axis) | ±0.020 mm | ±0.010 mm | ±0.005 mm |
Standard tolerances apply to non-critical features and general aerospace components. Precision tolerances are standard for structural fittings, mating surfaces, and hydraulic components. Flight-critical tolerances require specialized tooling, temperature-controlled machining (±0.5°C), in-process probing, and extended cycle times — reserved for turbine blade profiles, bearing surfaces, and safety-of-flight features.
Inspection & GD&T Verification
Aerospace parts require metrology equipment matched to the precision level of each feature. FIRMFG uses a multi-method inspection strategy combining tactile CMM, optical measurement, and surface profilometry. GD&T callouts per ASME Y14.5 are verified with automated CMM probe programs, including position, flatness, profile of a surface, and runout. Every flight-critical part includes a complete dimensional inspection report with ballooned drawing references, and First Article Inspection per AS9102 is provided for all new part numbers.
CMM Inspection
Zeiss-class tactile CMM with sub-micron probes verifies dimensional accuracy to ±0.003 mm. Automated probe programs measure GD&T callouts including profile of a surface on turbine airfoils. All flight-critical features are 100% inspected.
Optical Measurement
Non-contact optical measurement with 0.1 μm resolution for complex 3D surfaces, thin walls, and delicate features that cannot withstand tactile probing. Laser scanning verifies turbine blade profiles and airfoil geometry against CAD models.
Surface Profilometry
Contact and optical profilometers measure Ra, Rz, and Rt surface parameters per ISO 4287. Seal grooves verified to Ra 0.4 μm; bearing surfaces require Ra 0.2 μm. Every aerospace lot includes surface roughness certification.
Surface Treatment for Aerospace Parts
Surface treatments on aerospace parts serve critical functional purposes — fatigue enhancement through shot peening, corrosion resistance through anodizing and passivation, friction reduction through dry film lubricants, and defect detection through NDT. All processes comply with applicable MIL, AMS, and ASTM standards.
| Process | Standard | Typical Application | Notes |
|---|---|---|---|
| Anodizing Type III (Hardcoat) | MIL-A-8625 Type III | Aluminum 7075/2024 wear surfaces, structural parts — 50 μm oxide layer, 60+ HRC equivalent | Improves wear and corrosion resistance; dyed for identification |
| Passivation | AMS 2700 / ASTM A967 | 17-4PH stainless steel parts — removes free iron, forms chromium oxide passive layer | Required for all stainless aerospace parts per AMS-QQ-P-35 |
| Shot Peening | AMS 2430 / SAE AMS-S-13165 | Landing gear, springs, gears, fatigue-critical surfaces — induces compressive residual stress | Increases fatigue life by 5–10×; controlled intensity and coverage per spec |
| NDT — FPI (Fluorescent Penetrant) | AMS 2644 / ASTM E1417 | All flight-critical parts — detects surface cracks, porosity, and laps | Level A (post-machining) or Level B (post-finishing) per customer spec |
| Dry Film Lubricant | MIL-PRF-46010 / MIL-L-23398 | Sliding surfaces, fasteners, threaded joints — reduces friction and galling | Bonded MoS2 or PTFE coating; thickness 5–15 μm |
| Parylene Coating | MIL-PRF-46058 | Avionics boards, electronic enclosures — ultra-thin conformal barrier (1–50 μm) | Chemical vapor deposition; excellent moisture and dielectric protection |
Anodizing processes comply with MIL-A-8625 (Type III hardcoat). Passivation complies with AMS 2700 and ASTM A967. Shot peening complies with AMS 2430 and SAE AMS-S-13165. NDT processes comply with AMS 2644 (FPI) and ASTM E1417. All special processes are Nadcap-compliant, with process records included in the quality record package per AS9100D.
Selecting the Right Surface Treatment
For aluminum 7075-T6 structural parts, Anodizing Type III (MIL-A-8625) provides wear and corrosion resistance with a 50 μm hardcoat. For 17-4PH stainless hydraulic components, passivation (AMS 2700) removes free iron and forms the chromium oxide passive layer. For fatigue-critical landing gear and gear teeth, shot peening (AMS 2430) induces compressive residual stress that can increase fatigue life by 5–10×. For sliding surfaces and threaded joints, dry film lubricant (MIL-PRF-46010) reduces friction and prevents galling. All flight-critical parts require FPI (AMS 2644) to verify the absence of surface cracks after machining. FIRMFG engineers recommend the optimal treatment combination based on your part's function, material, and flight-criticality classification.
From Aerospace Prototype to Production
Aerospace programs move through distinct stages, each with different quantity, lead time, certification, and documentation requirements. FIRMFG supports the full journey — from a single prototype for design validation to full-scale production — with First Article Inspection (FAI) per AS9102 at each stage transition.
| Stage | Quantity | Lead Time | Certifications Required | Documentation |
|---|---|---|---|---|
| Prototype | 1 – 5 parts | 7 – 14 days | Material certs, dimensional report | FAI per AS9102 (optional), DFM report |
| Bridge Production | 5 – 50 parts | 14 – 21 days | AS9100D process, material certs, NDT (if required) | FAI per AS9102, CMM report, process plan |
| Pre-Production | 50 – 500 parts | 3 – 5 weeks | AS9100D, Nadcap processes, full NDT | Full FAI, control plan, PPAP-equivalent package |
| Production | 500+ parts | 4 – 8 weeks | AS9100D, Nadcap, ITAR (if applicable) | Recurring FAI, statistical process control, full traceability |
First Article Inspection (FAI) per AS9102
First Article Inspection is a mandatory verification process for aerospace manufacturing per the AS9102 standard. It requires documenting that the first part produced by a manufacturing process meets every dimensional, material, and process requirement on the drawing — not a sample, but a complete 100% verification. FIRMFG performs FAI on every new aerospace part number and whenever a significant process change occurs (new machine, new tooling, material lot change, or design revision). The FAI report includes a ballooned drawing with numbered characteristics, CMM dimensional data for every feature, material and process verification records, and NDT results. The complete FAI package is delivered digitally with the first parts, enabling your quality team to verify conformance before approving the process for production. FAI is mandatory for flight-critical parts and is recommended for all aerospace production runs.
Aerospace CNC Machining FAQ
Answers to the most common questions about aerospace CNC machining services at FIRMFG, including AS9100D certification, ITAR compliance, exotic materials, tolerances, traceability, and First Article Inspection.
QWhat is aerospace CNC machining?
Aerospace CNC machining is the precision subtractive manufacturing of aircraft, spacecraft, and defense components using computer-controlled multi-axis machine tools under an AS9100D certified quality management system. It encompasses 5-axis milling, turning, and EDM to produce parts from exotic materials such as titanium Ti-6Al-4V, Inconel 718, aluminum 7075-T6, and Waspaloy. Unlike general CNC machining, aerospace machining requires full material traceability (mill cert to finished part), First Article Inspection per AS9102, Non-Destructive Testing (FPI, X-ray, ultrasonic), ITAR compliance for defense articles, and Nadcap accreditation for special processes. Every flight-critical dimension is 100% inspected, with results documented in a comprehensive quality record package.
QIs FIRMFG AS9100D certified and ITAR registered for aerospace machining?
Yes. FIRMFG operates an AS9100D certified quality management system and is ITAR registered for the manufacture of defense articles on the United States Munitions List (USML). Our AS9100D certification covers the full aerospace quality lifecycle — design controls, configuration management, risk management, counterfeit-parts prevention, and traceability from raw material to delivered part. ITAR registration means we are authorized to manufacture and export defense-related aerospace components in compliance with U.S. State Department regulations. Additionally, our special processes (chemical processing and NDT) are Nadcap compliant, meeting the uniform audit standards required by major aerospace primes.
QWhat exotic materials can you machine for aerospace parts?
FIRMFG machines the full spectrum of aerospace-grade materials: Titanium Ti-6Al-4V (Grade 5) for turbine and structural components; Inconel 718 for high-temperature engine parts; Inconel 625 for exhaust and ducting systems; Aluminum 7075-T6 for structural members; Aluminum 2024-T3 for fatigue-critical wing and fuselage zones; 17-4PH stainless steel for hydraulic and actuator components; Hastelloy X for combustion chamber components; and Waspaloy for the most demanding turbine disk applications. All materials are sourced with certified material test reports (CMTR) including chemistry, mechanical properties, and heat lot traceability per aerospace material specifications (AMS).
QWhat tolerances can you achieve for aerospace CNC machined parts?
FIRMFG offers three tolerance grades for aerospace CNC machining: Standard at ±0.01 mm (±10 μm) for general features, Precision at ±0.005 mm (±5 μm) for mating surfaces and seal grooves, and Flight-Critical at ±0.002 mm (±2 μm) for bearing surfaces and high-precision features. Surface finishes range from Ra 0.8 μm (as-machined) to Ra 0.2 μm (precision ground/honed). 5-axis positional accuracy is ±0.008 mm with single-setup machining eliminating tolerance stackup from re-fixturing. All tolerances are verified using CMM (±0.003 mm accuracy), optical measurement, and GD&T analysis per ASME Y14.5. Flight-critical parts receive 100% inspection with results documented in the quality record package.
QHow do you ensure full material traceability for aerospace parts?
FIRMFG maintains complete forward and backward traceability for every aerospace part through a four-link chain: (1) Material Certificate — mill certification with heat number, chemistry, mechanical properties, and AMS specification per raw material lot; (2) Machining Record — process parameters, machine ID, operator, tool changes, and in-process inspection data for each operation in the routing; (3) Inspection Report — CMM, optical, surface roughness, and NDT results (FPI, X-ray, ultrasonic as required) with 100% verification on flight-critical features; (4) Special Process Records — shot peening intensity, anodizing thickness, passivation verification, and dry film lubricant bond testing. All records are compiled into a quality record package per AS9100D and delivered with the parts, enabling full traceability from mill certificate to final shipment.
QWhat is First Article Inspection (FAI) and do you provide it?
First Article Inspection (FAI) is a comprehensive verification process required by AS9102 for aerospace parts. It documents that the first part produced by a manufacturing process meets all drawing requirements — every dimensional, material, and process specification. FIRMFG performs FAI per AS9102 on every new aerospace part number and whenever a significant process change occurs. The FAI report includes: ballooned drawing with numbered characteristics, dimensional measurement results for every feature, material and process verification records, CMM data, and NDT results. FAI is mandatory for flight-critical parts and is recommended for all aerospace production runs. We deliver the complete FAI package digitally with the first parts, ensuring your quality team can verify conformance before approving the process for production.
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ISO 13485 certified medical CNC machining for surgical instruments, implants, and dental components. Biocompatible materials, sterile packaging, and full DHR documentation.
Learn MoreStart Your Aerospace CNC Project
Upload your CAD files and get a free aerospace CNC machining quote within 24 hours. Our aerospace engineers provide DFM feedback, material recommendations per AMS specifications, and process planning support at no cost. AS9100D certified quality, ITAR registered facility, 5-axis simultaneous machining, tolerances to ±0.005 mm, NDT inspection, and full traceability with every order. From single prototypes to production volumes, FIRMFG is your aerospace machining partner.