Mettis Aerospace 16pp Brochure

METTIS-AEROSPACE.COM

At Mettis Aerospace, we design and manufacture precision forged, machined components at our fully integrated facility at the heart of the UK, delivering to leading customers around the world.

Our vision is not only to be the best at what we do but to continually set new standards in the industry by investing and innovating. That’s why we have been pioneers in our industry for over seventy years.

Dedicated to our customers We are focused on delivering value for our customers, driving high levels of performance and eliminating waste through continuous improvements at every opportunity.

We enable our people to perform at their best at every level and to be: Pioneers: Be the future, today. Strive to be the best and lead our industry. Be innovative, creative, agile and responsive to what our customers need.

Be first to market with our innovations.

Professionals: Set the standards in everything we do and work with passion, pace, pride and precision to deliver quality consistently to our customers.

Partners: Collaborate in our teams, between our centres of competence and with our suppliers by engaging, inspiring, involving and respecting each other. Together we achieve more for our customers, delivering total value and giving competitive advantage.

Striving for excellence

We Are Mettis.

We are forging the future, today.

INTRODUCTION

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We have vertically integrated centres of competence that work together and innovate to deliver excellence.

That’s why we could give you the edge on your current and next generation programmes.

We are renowned for our quality, in particular, and work to some of the most exacting standards in the world.

We have AS9100 and ISO 9001 accreditation as well as Nadcap and extensive customer approvals.

We are forging the future with our integrated solutions

We are a leading designer and manufacturer of precision forged and machined components in titanium, aluminium, steel alloys and a range of specialist materials.

We provide world-class, integrated solutions from design and engineering to finishing and testing, simplifying the supply chain for our customers while offering total value, responsive delivery and quality.

In addition, we are continually investing and innovating to bring you the benefits of the latest technologies and processes which could give you a competitive edge.

All our operations are underpinned with robust business management systems and rigorous planning to help us deliver at the rates our customers need. We like to work as partners with both our customers and our suppliers so, together, we can develop the best solutions, deliver them on time, to cost and exacting standards.

Come to us with your challenges or requirements and our team will work with you to develop the optimum solutions for your precision forged and machined needs. 

solutions provided by our integrated facility We have a number of vertically integrated centres of excellence across our site which come together to deliver solutions for our customers. Each one is run by dedicated teams of people with extensive knowledge and experience who work to ensure our customers get the very best results.

Design and engineering Tooling Forging Machining Surface treatments and finishing Inspection and testing

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INTEGRATED SOLUTIONS

Our world-class design and engineering team develops optimum solutions Our dedicated design and engineering team works with specialists across our integrated facility to develop the best solutions for our customers. They design components, tooling and ancillaries to optimise production processes, maximising value and ensuring quality.

Whether you have a detailed specification, are coming to us with an outline challenge or something in between, our team will work with you to develop solutions and mature your designs. We use the latest technologies and trusted design systems including CATIA, Siemens NX and QForm 3D for rapid process development. We produce detailed scenarios, going through simulations which replicate planned production processes and 3D-print concept components to enable discussions around physical prototypes.

DESIGN & ENGINEERING

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We work with a diverse range of materials. Aluminium, steel and titanium are our most popular but we also use other specialist materials including magnesium, nickel and metal matrix composite.

Full life-cycle support We know that requirements and product specifications may change over time. Our robust engineering control processes enable continuous and concurrent development as customers mature designs in partnership with us.

Our design and engineering team enable you to make changes and corrections throughout the life of each component while ensuring continuity. We have the capability and capacity to deal with large packages and suites of work.

Talk to us about your challenges If you have an existing or upcoming forging or machining challenge, talk to us. We could help you develop the optimum solution for cost-effective production, on-time delivery and quality.

Using the latest simulation software, we design and then manufacture tooling in-house, reducing lead times and increasing the flexibility needed to satisfy customer requirements.

We manufacture, maintain and refurbish all tooling on site in our dedicated tooling facilities which are located close to our three forges. This enables us to have strong working relationships with the forging teams which helps streamline delivery and maintain quality control.

Our tooling facilities have extensive capability, operating a fleet of 10 Computer Numerical Control (CNC) machining centres and conventional machinery. Our highly-skilled tooling technicians produce over 1,000 dies a year.

Our dedicated, onsite tooling facilities help us deliver quicker

The investment and innovation we put into our tooling facilities are key to our success. Recent investments include a new CNC machining centre and an industryleading robotic contour-welding suite, complete with an integrated heat treatment facility. The die welding system, the first of its type to be installed in the UK, allows us to completely refurbish worn dies back to their working condition under CNC control to ensure repeatability of components.

A dedicated team also manages die maintenance with every die’s history and refurbishment planned and monitored as part of a robust resource plan.

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TOOLING

We can process all the core materials forged in house, including heat treatment which is generally applied to enhance strength and improve mechanical properties to achieve customer specifications. We also have the capability for ancillary operations including: Chemical cleaning/etching, abrasive blasting and barreling.

Our extensive forging facilities enable us to produce some of the most complex and intricate precision-forged components in the world.

Three onsite forges work with a wide range of materials including aluminium, titanium and steel alloys as well as other specialist materials. We excel at producing a wide variety of asymmetric and complex shapes while achieving the desired grain flow and mechanical properties to meet exacting customer specifications.

Anodising and surface treatments.

Destructive and non-destructive testing.

Inspection techniques are applied at key stages of production and prior to in-house machining or direct on-time delivery to customers.

We continually invest in developing new forging technology solutions to optimise material usage, maximise mechanical properties and cost effectiveness, using forging model simulation at the design stage. For example, we now use infra-red die heating to reduce changeover times and water-jet cutting to reduce non-value added processing.

We have a highly-skilled team of master forgers and over sixty forging units up to 12,000 tonnes including hydraulic presses, screw presses and hammers. We produce closed die forgings up to 250kg.

Our forging facilities have some of the best capabilities in the world FORGING

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Extensive machining facility delivers within the tightest tolerances Our onsite machining facility is so precise it can work to tolerances of 10 microns. We have a range of Computer Numerical Control (CNC) machines including 4 and 5 axis machines and a variety of spindles. They can work 24 hours a day on complex contours and features in single setups, enhancing delivery rates, adaptability and value.

We have dedicated product cells and optimise cycle times across multiple machines to reduce manufacturing costs.

We regularly invest in new machines to meet the growing number of machining orders we’re receiving. These machines have automatic loading, robotic arms enhance our automation capability, increasing further the rate at which we can deliver to our customers. In addition, they have in-process probing to reduce variables and enhance conformity without retrospective inspections.

Our technology enables us to provide solutions to complex machining challenges.

The facility is run by a team of highly-trained, machining specialists who have extensive experience of milling and turning techniques using aluminium, titanium and other lightweight metals.

We carry out audits throughout the process using Coordinate Measuring Machines (CMMs) and other equipment as well as rigorous checks at the end to ensure conformance and quality.

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MACHINING

NADCAP approved surface treatments and finishing services onsite We offer a range of surface treatments, and finishing processes carried out by highly-skilled, technical experts enabling us to deliver fully-machined and kitted components direct to final assembly lines. This offers added value and ease for our customers.

The services we offer include etching, enamelling and sub-assembly such as bonding rubber seals and applying other fittings.

Our finishing facility is fully Nadcap approved for a range of treatments and processes including: Chromic/sulphuric acid anodising (to AMS-A8625 standard).

Chemical cleaning; Solvent and Alkaline.

Chemical cleaning; Titanium.

Conversion/phosphate coatings.

Penetrant flaw detection.

Paint/dry film coating facilities.

We carry out a final quality inspection once all the finishing is complete before packing components with care ready to be delivered to our customers.

We have robust quality controls at every stage of manufacture which is why we are trusted to deliver high-integrity products and services to customers in heavily-regulated industries across the world.

FINISHING

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We deliver to the most demanding quality standards in the world

EXTENSIVE Industry accreditations and approvals AS9100 is a mandatory quality management system for the aerospace industry. Our AS9100 and associated ISO 9001 accreditation is demonstrated in our proactive and reactive quality assurance at every stage of manufacture. Our Process Effectiveness Assessment Reporting demonstrates our commitment to continually enhancing and developing cost-effective processes to deliver improvements right first time.

Our Nadcap approvals and merit status across many disciplines demonstrates our ability to meet and exceed industry-required ‘special process’ standards.

Our advanced testing facilities ensure quality We are proud of our onsite testing facilities which we use to carry out rigorous testing to ensure we meet customers’ requirements and the highest industry standards.

NADCAP approved chemical, metallographic and mechanical testing Our laboratory has Nadcap and ISO 17025 approval for all chemical, metallurgical and mechanical testing. The mechanical tests we carry out include room temperature tensile, fracture toughness, bend and impact. Recent investment includes a new Instron 350KN tensile test facility as well as a Leco 800 series multi-gas analysis unit for elemental analysis of titanium and other metal alloys.

Metallography work is carried out using the latest equipment for micro preparation and evaluation in our recently upgraded metallography suite which includes state of the art microscopes and image analysis software. Capability has recently been expanded to include an advanced Struers micro hardness tester. Metallography tests include grain size measurement, structural analysis, phase fractions, alloy depletion, surface contamination, coating thickness measurement and macro examination.

When specific material assessments cannot be completed on site, our technical team manages even the most comprehensive testing regimes through contractors or by hiring external facilities for our team.

Measurement equipment includes Coordinate Measuring Machines (CMMs), hard point measurement fixtures and projection units. We also invested in light-scanning technology recently, enabling us to scan measurements in seconds and get components on their way to customers faster.

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QUALITY

Extensive range of products and services T Clip Manifold Slat Rail

Spoiler Actuation Forging

Failsafe Link

Flap Carriage Beam

Annulus Filler Compressor Rotor Blade

Nacelle Fitting We manufacture an extensive range of precision forged and machined components for leading customers in the Commercial Aerospace, Military Aerospace, Defence, Helicopter, Rail and Marine sectors.

PRODUCTS & SERVICES

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Fan Retention Shaft

Compressor Vane

Door Lintle

Nose Landing Gear Drag Strut

Engine Pylon

Pylon R2

Nosewheel Undercarriage Part Nacelle

ESS Vane Tubeplate

Outlet Guide Vane Landing Gear Pintle Attachment Main Landing Gear Assembly

Wheels

Sidestay link

Rear Engine Pylon

These are just some of the components in our extensive range. We recommend the optimum, integrated solution for you.

If you’d like us to provide you with a full product list, more details on specific components or you’d like to talk to us about an existing, upcoming or next generation requirement, please contact us.

businessenquiries@mettis-aerospace.com

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PRODUCTS & SERVICES

Investing in research and technology

Research and development We are continually investing in research and development. We listen to our customers and work with them to develop new solutions for existing or upcoming challenges. If a proposed solution is agreed, we see it through every stage from development to deployment and work with customers on approvals.

All research and development activity is designed to deliver benefits for customers.

For example, we recently introduced a water-jet cutting facility which increases the speed at which some components can move between the forging and machining stages. Another recent investment is a robotic, contour-welding facility which enables us to accommodate certain last-minute design changes to dies which reduces customers’ development costs and allows us to begin delivering sooner.

Forging the future with New Product Introductions We are forging the future today with our dedicated New Product Introductions (NPI) facility with a stream of new products in development. We design solutions both in response to fresh customer challenges and in anticipation of what the market will need.

Our team builds intelligence into both components and manufacturing processes as we are always striving to deliver more for customers in the slickest possible way. We plan for growth and anticipate volume so we can ramp up as demand increases.

Talk to us about your challenges If you have an existing or upcoming forging or machining challenge, come and talk to one of our technical specialists. We could help you develop the optimum solution for cost-effective production, ontime delivery and quality.

RESEARCH & DEVELOPMENT

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PEOPLE People are the heart of our business and creating an environment in which they can thrive is important to us. It is how we keep delivering a great service for our customers and why we are leaders in our field.

Our leadership team has extensive experience in the manufacturing industry globally. They are true pioneers, leading the way by growing Mettis Aerospace into the forge of the future, today and extending our global presence.

We are proud of our team of talented leaders, experts and technical specialists. We’re committed to helping every member of our team reach their full potential and are investing in them every day through leadership programmes, apprenticeship schemes and development solutions for experts and technicians.

Under their leadership, we have continued to secure significant new contracts with leading customers as well as major investment in new technologies as part of our ambitious technology development programme. We have been first to market with many of the solutions developed. We are also expanding into new sectors.

We continually drive the highest levels of performance through inspiring leadership and robust management systems to maximise customer satisfaction. Our visual management systems, in particular, are some of the best in the industry and play a core role in ensuring we deliver to time, to quality and offer total value to our customers.

Gordon Fraser

Jeremy Cieslik

Phil Taylor

Phil Thornton

Chief Executive Officer

Chief Finance Officer

Chief Operating Officer

Commercial Director

People are the heart of our business and creating an environment in which they can thrive is important to us. It’s how we keep delivering a great service for our customers and why we are leaders in our field. businessenquiries@mettis-aerospace.com

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PEOPLE

Caring for the environment We are committed to continually enhancing our environmental performance with a focus on lowering energy and water consumption, reducing waste and protecting our local environment.

Most of our packaging and wooden pallets are returned after delivery so we can reuse them and we are working toward a target of recycling 70% of our waste.

There is a lake on our site which is home to a variety of wildlife. We take care of it and have a rest area nearby where employees can enjoy the view during their breaks. We also provide a ‘bike to work’ scheme for employees. It enables them to purchase a bike cost effectively, encouraging cycling to work.

We invest in innovative technologies and processes to save energy and reduce waste such as infrared die heating which uses significantly less energy than furnaces.

We care about the environment and local community CORPORATE RESPONSIBILITY

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Caring for our community We are proud to be based in the Midlands and to be the largest employer in Redditch. Many of our employees live in the town and we encourage them to get involved in the community. We also run occasional open days so people can learn more about what we do.

In addition, our employees inspire pupils at local schools through the Engineering Education Scheme. One of the groups we worked with came up with such a great efficiency idea that we’re currently in the process of adopting it.

We are passionate about supporting good causes and we have a committee that coordinates our fundraising activities.

We deliver to many leading customers in the Commercial Aerospace, Military Aerospace, Defence, Helicopter, Rail and Marine sectors.

We are continually innovating and developing new specialist processes. Each one goes through detailed testing and rigorous approval processes before introduction.

We welcome our customers on site for audits and inspections as often as they require.

For more information about our extensive customer approvals and how we can work with you, please contact us businessenquiries@mettis-aerospace.com

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CUSTOMERS

Whether you have an existing, upcoming or future requirement you’d like to discuss with us or have a general enquiry, please contact us today.

We’ll put you in touch with a technical expert who will ensure you get the support and answers you’re looking for, however small, large or detailed. We will work with you to find the optimum solution for your needs.

METTIS-AEROSPACE.COM Tel: +44 (0)1527 406400 Email: businessenquiries@mettis-aerospace.com Windsor Road, Redditch, Worcestershire, B97 6EF