FAQ's

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How many autoclaves are in your facility and what is the diameter and length of each?

Helicomb International currently maintains two 6' x 20' autoclaves 85psig and 100psig both rated to 450F and approved. We utilize AvPro software to monitor and control each autoclave run to insure parts are processed without defect. We maintain a robust maintenance program on those autoclaves. Additionally, we will be adding two autoclaves in the near future. We are looking at adding a 5' x 10' autoclave for smaller sized, low quantity part runs as well as acquiring an autoclave up to 10' x 30' to manufacture larger, complex assemblies at higher rates.

What is the size of your company's clean room facility?

Helicomb International's OEM and NADCAP approved clean room facility is approximately 11,000 square feet.

What is your company's tooling Fabrication Capabilities in the areas of A) Composites and B) Production Jigs?

A) Composites: We are in a position to design, manufacture and provide Complex Drill and route tools, ply lay up mandrels (PLMs) Various bond tools, ( bond assembly jigs) NC machined Master Models, Caul Sheets (Hard and Soft Composites) We can provide a complete tool string (Master Model, bond tool, route/drill, Various Ply Location templates, Assembly fixtures, Check Fixture-Media of Inspection Tools MOIs.

B) Production Jigs/Assembly Jigs: We are in position to fabricate production/assembly jigs for major assembly manufacturing (Composite or Metal)

What is your company's production capacity? Currently, at what level of capacity is the company performing? What about the next five years?

Our current capacity ranges in the 45-55% range. In the near future, we anticipate increasing our capacity with the addition of two autoclaves, Automation (Gerber cutters, Therm-wood Routers, Ply Orientation laser projectors, Etc.) We will continue Lean Manufacturing initiatives and Continuous Quality Improvement to improve processes and our personnel. This process has already begun and will continue over the next 5 years increasing our ability to do more for our customers.

What is the Company's Non Destructive Testing (NDT) scanning capabilities in the area of ultrasonic?

We utilize local ultrasonic NDT houses. We are exploring bringing ultrasonic NDT in house or acquiring a company dedicated to Non Destruct Testing to support our customer's quality and delivery expectations.

What is the Company's Non Destructive Testing (NDT) scanning capabilities in the area of X-Ray?

We utilize local OEM Approved X-Ray NDT houses.

What equipment does your company use for NDT?

We have access through our approved suppliers, X ray and ultra sonic (UT,RT) NDT to meet our customer's requirements.

What Type of Machining capability does your company have?

As part of the Synchronous Aerospace Group, we are in a position to offer Complex milling with 184 CNC milling centers, Gantries up to 200', several Multi-palleted 4 and 5 axis High Speed Horizontal systems and Large Nutating-head RB SNK. With respect to hard metal machining, we have 65 high torque, low speed spindles, with 33 of spindles being 5 axis. We are able to machine complex, small, medium and large components and assemblies. We also utilize large Niigata Horizontal 10 pallet systems. With respect to Turning, we have 69 turning centers, with the capability to turn from 0.125" to 12". We have experience on aluminum, hard metals, pure carbon and plastics. We can meet tolerances of 0.01" down to 0.0001". Additionally we have forming capabilities, Hydro, hot and cold joggle, Stretch, break and roll forming allowing us to produce complex sheet metal assemblies.

How large a part does your facility have the capability to machine?

We have the ability within the Synchronous Group to machine complex parts that are very small to large complex parts up to 200' in length.

Regarding Honeycomb Cores, what core carving machinery does your facility have?

For complex dimensional core requirements, we use our approved suppliers and receive core in kits. For basic non contoured core, we have in house capability to manufacture.

Does your company use Model based definition?

Yes, we use model based definition. We are DPD approved for The Boeing Company, Northrop Grumman, Spirit Aerosystems and Lockheed Martin. Software to support model based definition is Catia V4, V5-R16,17,18,19. We use Unigraphics NX5,NX6, Autocad, Solidworks and the Kubotek Validation Tool software. Additionally, we recently added a second FARO arm with the bridging software to CMM parts up to 20 ft. using Verisurf software.

What would be your Company's largest Bonded Assembly Capability?

We currently can manufacture bonded assemblies within our current autoclaves with diameters up to 4.5' and up to 18' lengths. Our future autoclave purchases will allow us to build significantly larger structures if we go with a 10' x 30' foot autoclave.

What has been your company's history in complexity of Assemblies? This question is in reference to trimming, drilling, countersink, fastener installation, sealing, priming and painting.

We have a 30 year old history of building complex bonded structures as described in question 13. We have all of those capabilities in house and perform those operations on a daily basis.

What has been your company's history in managing sub tier suppliers? Does your company have in place within your organization a team or department who is responsible to manage required processes at your sub tier supplier level?

We have a long history in managing our sub tier suppliers per our Quality Management system. We evaluate and monitor our sub tiers in our Quarterly Management Reviews, monthly and as needed. We monitor electronically and through site visits. We evaluate our sub tier suppliers on two basic metrics. They are Delivery and Quality. We have a team within our organization comprised of Quality and Purchasing professionals who are responsible to manage all sub tiers to insure required processes meet our customer's requirements