OEMs Turn to Duncan Manufacturing Solutions
In the demanding world of aviation, OEMs face constant pressure to innovate, maintain quality, and control costs. Increasingly, they are finding a valuable partner in job shop operations like what Duncan Aviation has developed in its Duncan Manufacturing Solutions, or DMS. As the largest privately owned business jet service provider in the world, Duncan Aviation started DMS to support its internal needs while providing service to business aircraft owners and operators. However, DMS is rapidly expanding to offer compelling solutions to aviation OEMs and even OEMs in other industries with complex fabrication requirements.
From a 21,000-square-foot, climate-controlled complex located at Duncan Aviation’s headquarters in Lincoln, Nebraska, DMS offers a compelling solution for OEMs seeking specialized expertise, flexibility, cost-effectiveness, and a commitment to quality.
“Our ability to fabricate high-quality complex parts is impressive, but it is a natural extension of Duncan Aviation’s 40+ years of manufacturing experience under our FAA PMA authorization,” says Scott Stenka, Duncan Manufacturing Solutions Manager. “We've long supported OEMs with interior components and bracketry, and now, with our advanced capabilities at DMS, we're taking on even more challenging projects. Our focus remains on innovation and creative problem-solving. We see opportunities where others see obstacles, leveraging our skilled workforce, in-house capabilities, and cutting-edge technologies to deliver effective solutions for our OEM partners.”
By partnering with DMS, OEMs can streamline their fabrication processes, maintain operational efficiency, and focus on their core strengths, ultimately driving innovation and success.
Specialized Expertise
Duncan Aviation has more than 40 years of manufacturing and engineering experience, FAA PMA (Parts Manufacturing Approval) authorization, and DER (Designated Engineering Repairs) experience. This wealth of expertise is particularly crucial in aviation, where stringent regulations and complex materials demand specialized knowledge. The ability to fabricate anything from support structures to interior aesthetic components demonstrates the versatility of DMS.
Flexibility & Customization
DMS is committed to innovation and problem-solving. This proactive approach is invaluable, especially when dealing with aging aircraft requiring out-of-production parts. DMS can handle projects from prototype to finished assembly, complete with customer data. This flexibility and customization extends beyond aging aircraft, assisting OEMs in creating unique, custom parts for new projects.
Cost Effective
When outsourcing to job shop operations, OEMs avoid the significant capital investment associated with establishing and maintaining fabrication capabilities. This, along with the ability to provide faster turnaround times, helps OEMs meet tight deadlines and manage budgets.
Quality And Industry Standards
DMS holds both AS 9100D and ISO 9001:2015 certifications. These certifications are the international standard for Quality Management Systems for aviation manufacturing organizations. They dictate system requirements with the challenges of the aviation industry in mind and are required for government and aviation parts manufacturing support contracts. The scope of these certifications are for sheet metal, composite, and precision-machined components, as well as specialized processes like welding and finishing, which allows DMS to meet the requirements of government and aviation parts manufacturing support contracts. The company is also in the process of obtaining NADCAP (National Aerospace and Defense Contractors Accreditation Program) accreditation.
Gogo: A Prime Example of OEM Partnership
Gogo, a leader in inflight connectivity and entertainment systems, turned to DMS as a resource to build the Gogo AVANCE L5 Broadband Internet and Wi-Fi kits.
“As the demand for inflight connectivity and bandwidth continues to surge, the efficient and reliable production of our AVANCE L5 kits is paramount," David Salvador, Vice President Aftermarket Channel. “Duncan Manufacturing Solutions has proven to be an invaluable partner in this endeavor. Their expertise in precision fabrication, coupled with their commitment to quality and timely delivery, directly contributes to our ability to meet the growing needs of our customers. We deeply value their contribution to the success of our Gogo AVANCE L5 program.”
These kits support Duncan Aviation-developed STCs and installation packages for the following business aircraft models, showcasing our ability to support complex, integrated solutions:
- Gulfstream G-IV, GIV-X
- CL600 Series
- CL300/CL350
- Dassault Falcon 2000/2000EX
- Dassault Falcon 900/900EX
- GLEX, GLEX XRS, GL6000, GL5000, GL5000 GVFD
- Cessna Sovereign
Nearly all the advanced manufacturing equipment and capabilities Duncan Aviation has in DMS were put to use fabricating the kits to support Gogo.
CNC Milling
CNC milling was used to create the contour plates for all model kits, often requiring multiple passes for parts with intricate specifications
Haas VF5, Haas VF6, and Haas UMC750 Five-Axis mills, along with an Epilog Fusion Pro 48 Dual Laser Engraver and a Haas ST-30Y Lathe, allow for the precise machining of complex parts.
Sheet Metal Fabrication
All flat sheet metal components of varying thicknesses were cut using an Omax 60120 Waterjet, while an Accurpress 7606 Press Brake forms sheet metal into desired shapes and angles.
Composite Manufacturing
For the Gogo AVANCE L5 kits, DMS bonds the components to the aircraft belly with composite materials, reinforcing the antenna’s installations. A state-of-the-art, positive airflow composite shop, complete with a clean room and paint booth, supports prepreg composite repairs and manufacturing.
Additive Manufacturing
A Stratasys Fortus 450MC 3D Printer is used to create tooling and drill fixtures to ensure accuracy when drilling panel holes for mounting contour plates and doublers. It is also used to create a mold for the press form beams for the CL300/350 kits.
Forming
A John Shaw Rubber Pad Press, utilizing molds printed with the 3D printer, press forms beams for the Gogo CL300/350 kits.
These aluminum parts are pressed in O condition, allowing for complex shapes and geometries. They are then heat-treated to final temperature.
Heat Treating
Two Delta H Heat Treat Ovens provide ample capacity for heat-treating components like the press form beams for the Gogo CL300/350 kits, ensuring maximum strength through controlled tempering, conductivity, and rock hardness testing.
Quality Control
With the use of precision equipment like the Zeiss Contura 12/18/10 Coordinate Measuring Machine with Vast XXT TL3 articulating sensor for multi-axis measurements, DMS ensures part accuracy, like the complex contoured parts associated with Gogo kit installs.
Beyond Manufacturing: Building Relationships
From prototype to production, DMS excels in job shop work, delivering high-quality precision parts tailored to complex specifications.
DMS is more than just a parts fabricator; Duncan Aviation wants to be considered a partner, building reciprocal relationships with customers and vendors alike. Whether the need is for a single part or a large production run, DMS is equipped to handle the challenge with a focus on quality, precision, and collaborative problem-solving. Experience and longevity in the aviation industry, combined with versatile capabilities, positions DMS as a unique and valuable resource for OEMs across various sectors.
Versatile and Comprehensive Capabilities
Duncan Manufacturing Solutions offers excellent manufacturing capabilities that include the following:
- Fabrication shop/machining
- Composite manufacturing/repair
- In-house quality control/inspection
- Full paint
DMS Customer Benefits
- AS-9100D and ISO 9001:2015 certifications
- Organized Delegated Authorization for STC (Supplemental Type Certification), MRA (Major Repair, Alteration and Airworthiness) and PMA (Parts Manufacturer Approval)
- Parts Manufacturing Authority
- FAA Repair Station
- Expedited Turntimes
- Prototype Service Capabilities
- Prototype-to-Production Capable with Customer Data
- CAD, CAMWorks and Solidworks Modeling Capabilities
- Certification and Consulting Services