Steel Cutting Blog

The aerospace industry relies on extreme precision to ensure the safety and performance of aircraft components.  

With its ability to cut through various materials and maintain tight tolerances, laser cutting has transformed how these critical parts are manufactured, offering unmatched accuracy and the ability to meet the industry’s strict requirements.  

At Amber Steel, we provide high-tech laser cutting solutions for even the most difficult projects – including in the aerospace industry. In this post, we’ll explore how laser cutting’s precision, efficiency, and automation are essential to modern aerospace manufacturing.  

The Evolution of Laser Cutting Technology  

Laser cutting technology has come a long way from its early days. Initially, cutting materials like metal required labour-intensive methods, often relying on manual saws or mechanical tools. These methods were slower, less precise, and prone to errors. As laser technology evolved, manufacturers began to embrace a more efficient, automated approach.  

Our current laser cutting machines are far more advanced. One of the most significant changes is automation, drastically improving efficiency and accuracy. In the past, operators had to manually control every aspect of the cutting process, carefully monitoring the machine to provide desired results.  

Modern laser cutters are equipped with automated systems that do much of the work (CNC), making the process faster and more reliable. Operators interact with user-friendly touch screens, similar to an iPad, controlling these machines with much more accessibility than ever. A few taps and swipes are all that are needed to perform complex cutting tasks that previously required hours of manual labour.  

These advancements are crucial for the aerospace industry. Aircraft components must meet incredibly tight tolerances; any deviation can lead to performance issues or safety concerns. Automated laser cutting allows aerospace manufacturers to consistently produce parts with exact precision so that every component fits perfectly within larger systems.  

By embracing this cutting-edge technology, our experts at Amber Steel can meet the aerospace sector’s specific standards with even greater reliability and efficiency. As advancements continue, laser cutting will remain a driving force in the aerospace industry, offering unmatched results.  

Precision and Accuracy in Aerospace Parts 

Precision is crucial in aerospace manufacturing, where components like turbine blades and engine parts must meet exacting standards to ensure safety, performance, and regulatory compliance. Even minor dimensional changes can impact an aircraft’s performance or safety. 

Laser cutting excels at achieving tight tolerances, essential for parts like turbine blades and engine components, which require precise manufacturing to function efficiently and endure the extreme conditions of aircraft engines.  

Laser cutting can easily handle these requirements, making every part with exact specifications.  

Key Benefits of Laser Cutting for Aerospace Parts Include: 

• Tight tolerances: Laser cutting achieves the exact dimensions required for components such as turbine blades, engine parts, and more. This perfectly fits complex assemblies, allowing optimal engine performance, reduced vibration, and increased durability. Aerospace parts often demand tolerances within fractions of a millimeter, which laser cutting consistently delivers. 

• Complex geometries: Many aerospace components, like jet engine blades, require intricate and often irregular shapes that traditional cutting methods struggle to replicate. Laser cutting allows for incredibly detailed designs, making it ideal for producing parts with complex geometries that would be impossible to achieve with conventional methods. This creates high-performance components that meet the precise aerodynamic requirements of modern aircraft. 

• Minimization of errors: Automation in laser cutting reduces human error, creating parts that are cut to exact specifications. This results in fewer defects, less material waste, and higher overall quality, all critical for aerospace safety and performance. Consistency in production also means reduced downtime for inspections or corrections, leading to faster turnaround times. 

Amber Steel leverages cutting-edge technology to manufacture unmatched precision and quality aerospace components. We adhere to the industry’s highest performance standards, ensuring every part we produce is safe, reliable, and exceeds our clients' expectations. 

Efficiency and Productivity in Aerospace Manufacturing 

Laser cutting technology is essential for accelerating production timelines in comparison to traditional methods like manual cutting or mechanical processes. With its ability to cut quickly and accurately, laser cutting reduces the time it takes to manufacture intricate aerospace components, keeping production on track and completing projects faster.  

One of the standout features of laser cutting is its versatility in materials. Aerospace manufacturing often involves working with various metals, including titanium, aluminum, and high-temperature alloys. These materials create lightweight, durable, and heat-resistant parts used in aircraft.  

Laser cutting excels at handling these metals, delivering clean, precise cuts without damaging the material. This ability to cut through various metals efficiently allows manufacturers to produce parts that meet the exact specifications needed for optimal performance in the aerospace industry.  

Automation’s Role in Increased Output 

Automation has taken laser cutting to a new level of productivity. Manufacturers can achieve high-speed workflow with minimal downtime by integrating laser cutting machines into production lines. Automation allows for continuous operation, with machines handling complex tasks while reducing the need for constant manual supervision. This helps production run smoothly, even during large-scale projects.  

In addition, automated systems can switch between different tasks quickly, creating multiple designs in a rapid time frame without the need for physical tooling adjustments. This flexibility is valuable in aerospace manufacturing, where custom parts are frequently required. The ability to reprogram machines in the span of seconds, combined with plenty of operational hours, drastically increases output.  

With advanced laser cutting technology, Amber Steel efficiently handles large production demands while maintaining top precision and quality. We can meet tight deadlines without compromising component quality by combining speed, material versatility, and automation.  

Cost-Effectiveness and Material Efficiency 

Managing costs while maintaining high-quality results is highly demanded in aerospace manufacturing. Laser cutting technology offers significant advantages in terms of cost-effectiveness and material efficiency, making it the preferred choice for producing aerospace components.  

• Reduced Material Waste: One of the key benefits of laser cutting is its remarkable precision, which minimizes material waste. Reducing waste is important in aerospace manufacturing, where materials like titanium and aluminum are expensive. Laser cutting creates exact cuts with minimal excess, allowing manufacturing to maximize the use of each sheet of material. This cuts down on waste and lowers overall material costs, making the production process more economical.  

• Lower Labour Costs: Automation reduces labour costs, unlike traditional cutting methods that require multiple operators to oversee the process. Laser cutting systems are automated, meaning fewer operators are needed, leading to a reduction in labour expenses. Our investment in laser cutting technology allows us to maintain efficiency with fewer hands-on deck, passing those savings on to our clients.  

• Longer Tool Life: Laser cutting eliminates the need for physical cutting tools, which means there is less wear and tear compared to mechanical methods. Traditional cutting tools need regular replacement, leading to downtime and higher costs. With laser technology, the lack of direct contact with the material extends the lifespan of the cutting system, reducing maintenance costs.  

Combining material efficiency, reduced labour, and lower maintenance costs, Amber Steel delivers high-quality aerospace components at a competitive price, providing significant value to our clients.  

Environmental Sustainability in Aerospace Manufacturing 

The shift to environmental sustainability is becoming increasingly important in aerospace manufacturing, and laser cutting technology has implemented these practices to help reduce its environmental footprint. Laser cutting offers a more sustainable manufacturing process by combining precision, efficiency, and eco-friendly practices.  

• Reducing Material Waste: One of the most effective advantages of laser cutting is its ability to minimize material waste in aerospace manufacturing, where materials like titanium and aluminum are costly and resource-intensive to produce. Laser cutting’s precision allows manufacturers to maximize the use of each sheet of material, reducing waste and lowering the environmental impact.  

• Energy Efficiency: Modern laser cutting machines are designed to be energy-efficient, consuming far less power than older mechanical cutting methods. In aerospace, where production runs continuously and on a large scale, this energy conservation is essential. Laser cutting’s energy efficiency not only reduces operational costs but lessens the environmental impact of large-scale manufacturing.  

• Minimal Emissions: Laser cutting is a cleaner process, unlike traditional cutting methods that generate excessive heat or use harmful chemicals. It results in fewer emissions and a smaller carbon footprint, making it a more environmentally sustainable choice for aerospace manufacturing.  

• Recyclable Waste and Eco-friendly Material Usage: The small amount of scrap metal produced by laser cutting is easily recyclable. Additionally, laser cutting’s precision allows manufacturers to use thin-gauge materials, reducing overall material use without sacrificing durability. This helps the aerospace industry create lighter, more fuel-efficient components, further promoting sustainability.  

In aerospace manufacturing, laser cutting offers unmatched precision, efficiency, and sustainability. This advanced technology is crucial for producing high-quality components that meet the industry’s strict standards, from reducing material waste and cutting costs to supporting environmental goals. Amber Steel is equipped to handle your laser cutting needs—contact us today to learn how we can support your next project.

Valued at $321.5 billion US in 2022, the global aerospace market is expected to increase to $678.17 billion by 2032. That’s a compound annual growth rate of 7.80% from 2023 to 2032. 

Aerospace as an industry has always thrived off the human desire for exploration and to learn more about the “final frontier.” We strive to know more about existence as a whole, which means travelling beyond the Earth’s atmosphere and reaching for the stars. 

More pragmatically, however, factors such as an expanding commercial aviation sector and needs surrounding security and defence are primarily driving growth in aerospace. 

So, involving your company in aerospace is a decision seemingly bound for success (if you do everything right.) You’re getting involved in a sector where the ceiling is jaw-droppingly high.  

The above notion applies to aerospace parts manufacturing – a multibillion-dollar industry extending to cabin interiors, equipment, aerostructures, engines, etc. 

While the chances for a healthy bottom line in this sector are highly enticing and feasible with a healthy dose of expertise and hands-on precision, there are many caveats. In this article, we will explore the intricacies of aerospace parts manufacturing and the role of plasma cutting in achieving its strict specifications. 

At Amber Steel, we specialize in laser, plasma and flame cutting, and have always been a "total source" service for the production of quality steel products. Quality is achieved by utilizing the right production technique for the right product. Our continual investment in equipment and technology enables us to offer clients many production alternatives to achieve exact product specifications and tolerances. If you’re interested in learning more about steel cutting or have a project in mind that you would need our expertise on, do not hesitate to reach out. We’re always one email or phone call away.   

Aerospace: an Industry With Stringent Specifications 

Anybody looking to make their mark in the aerospace industry will face demands that include: 

• The rigidity of specifications. 

• Extremely high component quality standards. 

Aircraft and spacecraft encounter extreme conditions during their operations and can’t be failed by their nuts and bolts. They need robust, durable, and reliable components that withstand and operate reliably, regardless of the situation. 

Let’s delve further into some challenges aerospace components must face: 

• Extreme temperatures (e.g., intense engine-area heat and the glacial, sub-zero conditions in space or at high altitudes) put aerospace components under continual duress. 

• Pressure changes continually inflict themselves upon components, which must endure during such instances (e.g., during takeoff, spacecraft re-entry, or cruising at high altitudes).

• Mechanical stress causes intense vibrations during flight takeoffs and landings, calling for enhanced durability and robustness of parts. 

Suppliers and manufacturers must meet – and preferably exceed–these intensive, highly rigorous standards. Those successful in doing so will have a competitive edge in the market, enjoying a steady line of long-term clients and fruitful revenue streams. 

Aerospace Industry Materials and the Role of Plasma Cutting 

Plasma cutting uses accelerated hot plasma jets to cut through electrically conductive materials.

It’s used in aerospace because it has the following properties: 

• Plasma cuts through aluminum alloys (preferred in aerospace due to their lightweight, strength, and resistance to corrosion) with superior thickness. It cuts through aluminum up to 160mm (compared to the 25mm of laser cutting). Its equipment and operating costs are also lower.

  • 2024, 7075, and 6061 are aluminum alloys used in aircraft skins, engine parts, and frames, popular for high-performing strength-to-weight ratios.  

• Plasma-cutting manufacturing for titanium alloys (a lightweight, strong, and corrosion-resistant material) is ideal for hard-to-reach angles. It also shines for hard-to-fit parts. Titanium is used in airframes and jet engines, holding firm against high temperatures.  

• Nickel Alloys–especially Inconel, a nickel-chromium alloy–maintain strength over a wide temperature range. Thus, they’re commonly found in turbine engines. Plasma cutting can reduce material hardness, helping enhance the cutting process with tools. 

• Magnesium alloys are vital in weight reduction (e.g., gearbox casings and interior aircraft components). However, flammability and corrosion issues limit their usage. Plasma cutting cuts magnesium at higher speeds and lower operational costs than other methods. 

• Copper alloys have excellent electrical conductivity and are, as such, implemented into electrical components and heat exchangers/cooling systems. Plasma cuts through copper faster than other methods while maintaining precision, making it ideal for large-scale projects. 

• Carbon fibre, reinforced polymers, and other composite materials offer an alternative to metals in aerospace due to their lightness in weight, high strength, and ability to stave off corrosion. Found in airframes, wings, and interiors, composite materials benefit from being cut with plasma due to precision and repeatability.  

• Highly complex superalloys are based on nickel, cobalt, or iron, found in chromium, molybdenum, and titanium to enhance properties. As discussed beforehand, Inconel (a superalloy) is typically utilized in aerospace manufacturing. Hastelloy is, as well. Plasma can cut hastelloy safely, seamlessly, and quietly, more than other cutting methods like arc air.  

Precision and Tolerances 

Precise dimensions are absolutely vital when creating products for aerospace parts manufacturing.  

The margin for error is non-existent, and the extreme conditions encountered in aerospace operations call for rigorous attention to detail. 

Pressure and air resistance are critical factors for aerospace vehicles and the environment in which they operate. Optimal aerodynamic performance–yielding enhanced overall performance and fuel efficiency–relies upon precise dimensions.  

A lack of dimensional consistency will dwindle away at a component’s structural integrity, causing vulnerabilities and potential failure when faced with stresses like fluctuating atmospheric conditions and high speeds.  

Components must meet stringent quality assurance and testing standards to be certified for aerospace applications. This includes having precise tolerances and dimensions.  

Safety, performance, cost-efficiency, regulatory compliance, and fostering industry-wide technological growth all rest on exact dimensions and minimal error margins. No compromises can be made in any of these aspects, or else there’ll be catastrophes, increased costs, and other seismic consequences. 

Regulatory Compliance 

These fundamental standards and certifications are all relevant to the aerospace parts manufacturing industry: 

• The AS9100 Series is widely adopted by the aerospace industry as the standardized quality management system. 

  • This quality management standard applies to manufacturing processes, ensuring regulatory requirements and customer expectations are met. 

• ISO 9001 is a global quality management system standard that includes aerospace and is typically a manufacturer's base-level requirement. 

• NADCAP (National Aerospace and Defence Contractors Accreditation Program) provides specific process accreditation (e.g., for coatings, welding, or non-destructive testing) and can extend to plasma cutting aspects. 

• FAA (Federal Aviation Administration) Regulations apply to the US and involve aeronautical maintenance and manufacturing. Compliance with these regulations is crucial if plasma cutters/parts manufacturers want their parts used in the US. 

• EASA (European Union Aviation Safety Agency) Certification is the same as the FAA, except it instead applies to the European Union’s aviation safety standards. These standards must be followed if you want your manufactured parts to reach the European aerospace market.  

• AMS (Aerospace Material Specifications) Standards specify aerospace materials, practices, and processes. They’re developed by SAE International and generally apply to any cut and processed materials in the aerospace manufacturing sector.  

• ASTM International Standards apply to vast services and materials, extending to aerospace manufacturing processes. 

• MIL-Spect (Military Specifications) are physical and operational characteristic standards for military-grade products. They impact manufacturers who work in the defence aerospace industry. 

• ITAR (International Traffic in Arms Regulations) and EAR (Export Administration Regulations) compliance are US regulatory standards that oversee the manufacturing, exporting, and transfer of articles and services relating to defence. Manufacturers working in aerospace defence must familiarize themselves with these regulations. 

Why Plasma Cutting and Aerospace are the Ideal Combination 

Here’s a list of why plasma-cutting manufacturing and aerospace present a synergistic combination: 

• Precision: Plasma cutting for aerospace is an ideal fit due to its precision–especially the cutting-edge high-definition plasma offered at Amber. Plasma’s ability to maintain this accuracy through varying thicknesses means plasma cutting manufacturing can rise to aerospace’s rigorous dimensional and tolerance specifications.  

• Productivity and Efficiency: Plasma cutting presents the best of both worlds–speed and accuracy. Thus, it’s a crucial difference-maker in large-scale production. 

• Cost-Effectiveness: Plasma works faster than laser cutting (for instance) while delivering top-tier results. That means less work yielding more results, saving money on labour. The precision of plasma cutting also reduces waste materials–you only use what’s needed, meaning you only spend what’s needed. Regarding energy efficiency, it offers a 1:2 ratio per cut versus oxygen cutting. 

• Flexible Customizations: Plasma machines often focus on producing custom metal parts and patterns. Aerospace and engineering have unique specifications for almost every piece of equipment involved. The specificity of plasma to provide unique results of the highest possible quality makes it ideal for such a scenario.  

Challenges to Navigate 

Below is a set of challenges that must be navigated with plasma cutting for aerospace: 

• The tight tolerances and required accuracy in aerospace can sometimes outweigh the capabilities of plasma cutting. Intricate designs with exceptionally thin materials can lead to issues.  

• The high temperatures in plasma cutting can lead to the material’s thermal distortion–a massive problem in aerospace manufacturing. Dimensional accuracy and integrity are crucial, and minimizing heat-induced warping is a continual obstacle.  

• When temperatures rise during plasma cutting, the material’s integrity and properties (e.g., tensile strength or hardness) can be adversely impacted. The aerospace industry relies on those properties being optimized.  

• Aluminum, titanium, and other non-ferrous metals appear in aerospace frequently and often pose plasma-cutting challenges because of their reflexivity, which hampers the cutting process.   

• The re-solidified oxidized material, dross, forms on cut edges when plasma is used–a significant issue. Dross-free cuts are a must to avoid additional finishing processed in aerospace parts manufacturing.  

• In some instances, plasma cutting can lead to surface irregularities and roughness, generating stress concentrations which could hamper a part’s structural integrity.  

Want to offset these challenges while maximizing the benefits of your plasma-cutting parts manufacturing? Partner with Amber Steel. Contact us today to learn more.