www.djgrp.com Call 316-775-1212

MANUFACTURING LEADER

DJ Engineering Inc. is a leading manufacturer in aerospace and defense. We employ over 300 people in a 300,000 square-foot facility. Based in Augusta Kansas, DJE is a premier manufacturer for complex machined parts, sheet metal fabrication, large assemblies, composites, extrusions, various types of hot forming and reverse engineering to support the aerospace and defense Original Equipment Manufacturers (OEM).

MRO SOLUTIONMaintenance, Repair and Overhaul

COMPOSITES SERVICES

DJ Engineering repair station is FAA/EASA- Certified since 2009, offering comprehensive aircraft maintenance, repair and overhaul services (MRO). DJ offers component service, maintenance, refurbishment for airframe structural repair, landing gears overhaul, actuators, composite repair, and inspections. DJ does all it can to add value to components, extend the time between overhaul and expedite turnaround time.

D-J Engineering has an advance composites facility specializing in composite and bonded metal components. Facility is approximately 60,000 sq. feet and equipped with Laser projection and 2 autoclaves. DJE is currently capable of processing large composite assemblies. DJ's positive pressure 80 x 45 ft. Class 100,000 clean room (100,000 particles of .5 micron size per cu. ft.) has internal cold storage and CNC ply-cutting facilities.

•DJE was established in 1992 supporting the aerospace industry.

•DJE specialized in Manufacturing, Aircraft maintenance, Repair and Overhaul

•DJE is 100% committed to Quality, On-time delivery, and Customer Satisfaction

•DJE is globally located in 5 locations.

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Machine Facts CenterCategory Description Size

6-Axis Jomach Horizontal – 7,500 RPM 1104" x 120" x 96"

6-Axis Jomach Horizontal – 7,500 RPM 1104" x 120" x 96"

5-Axis 360° Dual Head Independent “Y” Axis 4,500 RPM 720” x 160” x 55”

5-Axis 360° Dual Head Independent “Y” Axis 4,500 RPM  

5-Axis 3 Spindle Gantry – 4,000 RPM 720" x 120" x 48"

5-Axis FZ-30-5 Bridge 360° Head – 18,000 RPM 160” x 112” x 40”

5-Axis 30V Rail 10,000 RPM 480" x 70" x 25"

5-Axis 30V Bridge 4,000 RPM 168" x 70" x 25"

5-Axis 800 7,000 RPM 80" x 36" x 36"

5-Axis PC 60/V 4,000 RPM 60" x 20" x 20"

5-Axis PC 120/V 4,000 RPM 120" x 50" x 36"

5-Axis SL-V50 Plus Waterjet  

5-Axis Seramill 90° Head 4,000 RPM 315" x 93" x 39"

5-Axis Milling machine  

5-Axis Milling machine  

4-Axis HM-80S incremental dual pallet rotary table 15k RPM  

4-Axis ACE-H100 dual pallet/dual table indexing 4500 RPM  

4-Axis A77 incremental dual pallet rotary table 10,000 RPM  

3-Axis VMC 4000GT-DW 2 Spindle 4,000 RPM 160" x 102" x 32.3"

3-Axis V3100 4000 RPM 120" x 39" x 32"

3-Axis High Velocity 4,500 RPM 240" x 36" x 30"

3-Axis 2000P 4,000 RPM 80" x 36" x 36"

3-Axis MCV-760BP 4,000 RPM 30" x 20" x 20"

3-Axis 100HP Dual Head Abrasive Flo-WaterJet  

3-Axis TV 146 55" X 24" X 25"

D-J Engineering, Inc. CNC mills range in size from small 3-axis mills and

lathes to huge 5-axis gantry machines, capable of producing parts up to

60’ in length.

Machining/Milling

Large Cargo FreighterLower Fwd. Main HingeRaw Material: Stainless Steel15-5 PH Forging: Approx. 7000 lbs.Machined to 600 lbs. final product

We have acquired and maintain a variety of equipment to ensure

that we can produce nearly anything. Our large 5-axis CNC mills

allow us to produce complex parts with fewer setups and

increased accuracy. Our smaller 3-axis mills and our 4-axis pallet

centers help to provide the right machine for those smaller parts

with tight tolerances. We buy equipment strategically to not only

add capacity, but also capability.

50” Titanium Hog out

80” Long Hog out

15-5 PH Stainless Steel Engine Mount.

Machining/Milling

The Real Deal WIP

AssembliesD-J Engineering has completed assemblies such as the

B-52 Engine Strut, KC-135 Crew Entry Doors and Spoilers, FA-18 Blue Angel Oil Tanks, the 767 Tanker/Transport Floor Beam Assemblies, and the Aerial Refueling Boom Structure and Skins. As an “Integrator” D-J Engineering, Inc. has developed a top-notch assembly team.

Assemblies

20 Sub Assemblies• 170 Hardware Items• 251 Detail Parts, consisting of:- 25 Machined (casting, plate, bar, etc..)- 67 Alum. Extrusions- 110 Alum. Sheet Metal- 7 Steel Sheet Metal- 17 Items Purchased Complete (springs, shims, etc…)- 25 Misc. Manufactured Items (tubing, phenolic sheet, etc..)

100% of the parts for both projects were fabricated in house, using DJE owned resources exception to this rule being painting and NDT.

Assemblies

100% of the parts for both projects were fabricated in house, using DJE owned resources exception to this rule being painting and NDT.

Assemblies

100% of the parts for both projects were fabricated in house, using DJE owned resources exception to this rule being painting and NDT.

INTRODUCTION DJ COMPOSITES

ISO 9001:(2008); AS9100B NADCAP – Composites Commodity Boeing (BAC5317, BAC5317, D6-49327 ) Bombardier Aerospace – (Complex Composite Assemblies) GKN Westland Helicopters - Q500 Quality Approval (Flight Critical Components) Augusta AQM-002A Quality Certification Sikorsky S2000 Transport Canada / FAA Approved Manufacturer Transport Canada / EASA Approved Maintenance Organization

Position AccuracyShort range: ± 0.015” (0.38mm) or better at a

distance of 17’ over 17’ x 17’ (5.1m x 5.1m) area

 Long range: ± 0.015” (0.38mm) or better at a

distance of 17’ over 17’ x 17’ (5.1m x 5.1m) area; ± 0.030” (0.76mm) or better at a distance of 30’ over 30’ x 30’ (9.1m x 9.1m) area

DJ Composites is equipped with Network Multitasking System three-dimensional laser templating and positioning system. It accurately projects a virtual laser template onto molds and parts to guide operators through the process of part fabrication. Eliminates the need for physical templates improving accuracy and throughput, reduces costly rejects, saves set-up time, and allows the assembly of multiple parts simultaneously. LaserEdge Multi-Task enables one projector to serve multiple worksta tions so ply layup on multiple parts can occur in parallel.

DJ COMPOSITE Virtek LaserEdge Templating System

DJ COMPOSITE

Composite Assembly

RJ Tail cone Assembly – wire harness, antennae mount and navigation light installation

Auxiliary Fuel Tank Assembly

DJ COMPOSITE

Composite Assembly

RJ Tail cone Assembly – wire harness, antennae mount and navigation light installation

Auxiliary Fuel Tank Assembly

DJ COMPOSITE

Laminates

Complex Composite Structures

Ducts (wash-out mandrels)

DJ COMPOSITEComposite Tool Design

and Manufacture

Master Mould Machining Graphite Epoxy Tool Manufacture Construction of tooling aids

DJ COMPOSITE Metal Bonding

Aluminum and Stainless Steel Bonded Panels

DJ COMPOSITEAutoclave and Batch Oven

30’ x 10’ diameter Autoclave Batch Oven Cure Dual Daylight Press Cure

DJ COMPOSITENon-Destructive Testing

Real Time X-Ray C-Scan and A-Scan Microscopic Analysis

Extrusion SolutionsAluminum extrusions are one of the basic building blocks of airplanes. DJE has the extrusion solutions for custom production runs of aircraft alloy aluminum extrusions.

Cost-effective: Raw material waste saving * Low setup cost * Short lead time

Versatile: Extrusion technology can create intricate shapes, with hollows, thin walls (down to 0.020"), fastening faces, and other complex features integral to the part with no additional assembly.

The best products require a great understanding of what the needs truly are. You will experience personalized service, and a quality that is above the rest with DJE.

•High quality •Certified aluminum materials

With two extrusion presses (1400 and 2200 ton), we can do small or large extrusions up to 10” in diameter. We’ve adapted our larger press to do pierced hollow extrusions.

Custom Die Solutions

DJE extrusion press maintains steady force on the billet, depending on the complexity and weight of the extrusion profile and ram speeds of the aluminum extrusion press can produce 50 to 100 extrusions per day. The benefits of this system include:

•Reduce dead cycle time from billet to billet •Maintain straightness of product being extruded •Minimize scrap

Extrusion Press Handling System

Inspection & Quality assuranceOur products fly.Quality is non-negotiable.As an ISO-9001 and AS 9100 certifiedsupplier, we take pride in delivering onlythe best. If you have unique qualityrequirements, we will cooperate with yourteam to make certain that your standardsbecome ours.Precision products require precision tools.We have two Coordinate MeasurementMachines (CMM’s), four Laser Trackers, ahand-held optical laser scanner, hardness and conductivity meters.

• Ultrasonic Inspection

• Through Transmission

• Pulse Echo

• C-Scan

• Eddy Current

• Magnetic Particle

• Dye Penetrant

• Conductivity Testing

NDI/NDT CAPABILITIES and equipment

D-J Engineering, Inc.219 W. 6th AveAugusta, KS 67010Telephone: (316) 775-1212Fax: (316) 775-4840

Visit us www.djgrp.com

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