How a Customer Used Our Expander Machine to Build Helicopter Cowlings for Aerospace Manufacturing

UncategorizedTags: aerospace fabrication, aerospace manufacturing, expander machine, forming machinery, helicopter cowling fabrication, helicopter parts, Metal Forming, ring expansion machine, segmented expander, Sterling Machinery customer story, used metal expanderNo brands

How a Customer Used Our Expander Machine to Build Helicopter Cowlings for Aerospace Manufacturing

When it comes to precision forming in aerospace, having the right equipment can make all the difference. In this story, we highlight how one of our East Coast customers, Mark, upgraded his operations with a multi-segmented expander from Sterling Machinery to fabricate high-quality helicopter cowlings. Here’s how this machine is helping him keep things flying high.

Meet the Customer

Mark is an experienced aerospace parts manufacturer based on the East Coast, working primarily within the helicopter sector. Operating out of the 206 area code, Mark and his team are focused on crafting top-tier components for helicopter assemblies, especially custom-fitted metal cowlings. With a reputation for precision and consistency, Mark knew he needed a forming solution that could keep up with tight tolerances and production timelines.

Goal

Mark’s main objective was to find a forming machine capable of expanding metal rings and cowlings for helicopter applications. His team needed a solution that could handle a range of part sizes and materials while maintaining structural integrity—critical in aerospace applications. The ideal machine had to offer flexibility, repeatability, and speed to meet growing production demand.

Process

After researching forming equipment that could meet his strict aerospace manufacturing standards, Mark came across our Used Multi-Segmented Expander—a versatile machine designed to handle everything from appliance housings to jet engine rings.

Here’s how he integrated the expander into his process:

1. Initial Setup: Mark’s team adjusted the machine to accommodate the size and thickness of their aluminum and titanium ring blanks.

2. Custom Dies: They used precision-milled tooling to ensure that each expansion operation would match the cowling specs needed for different helicopter models.

3. Quality Control: After expansion, each piece was measured and inspected to meet FAA standards for aircraft parts.

4. Production Scaling: The ease of repeatability allowed Mark to scale up production without sacrificing quality.

Experience

Mark shared that the multi-segmented expander exceeded his expectations. Not only did it reduce forming time significantly, but it also improved the consistency of their parts, which is crucial for aerospace safety. The machine’s ability to handle heavy-duty forming with minimal operator intervention made it a perfect fit for their facility. He mentioned that it was “one of the smoothest machinery integrations we’ve ever done.”

It’s Always a Positive Experience with Sterling Machinery

This story is just one example of how the right machine can empower a business to grow and meet the demands of a complex industry like aerospace. At Sterling Machinery, we take pride in matching our customers with equipment that truly fits their needs. If you’re looking for an expander or metal forming machine, check out our Expander Machines and Forming Equipment pages to browse our current inventory.

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