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Fuzing & Precision Products
Kaman Aerospace Group
Aerosystems
Specialty Bearings & Engineered Products
Air Vehicles & MRO
Metallic's & Assembly
Composite Structures
Annual Sales $1.6 BN
4,800 Employees
Headquarters: Bloomfield, Connecticut
Listed on NYSE: KAMN Company Restricted
Engineered Products
Engineering Services
Greg Steiner President
Jim Larwood
President
Jerry Ricketts Division President
Precision Products
Rob Paterson Division President
Speciality Bearings
Bob Manaskie General Manager
Cliff Ward VP/General Manager
Bob Kanaskie Division President
Al Lariviere Division President
Kaman Aerospace Worldwide Locations
Helicopters
Precision Products
1. Middletown, CT
2. Orlando, FL
3. Tucson, AZ
4. Bloomfield, CT
5. Dachsbach, DE
13. Jacksonville, FL
14. Chihuahua, Mexico
7. Bloomfield, CT
8. Wichita, KS
9. Lancashire, UK
10. Bennington, VT
11. Goa, India
Company Restricted
Aerosystems Engineered Products
Fuzing & Precision Products
Specialty Bearings & Engineered Products
Air Vehicles & MRO
Metallic’s & Assembly
Composite Structures
Engineering Services
6. Bloomfield, CT
12. Everett, WA
India (JV)
Lo-cost
Slovakia
Lo-cost
Chihuahua
Lo-cost
Lo-Cost (options)
India: Composites
Chihuahua: Metallic’s
Slovakia: Tooling Fabrications
Kaman Aerospace Group Aircraft Product Portfolio – Fixed Wing
Doors (inc MLG & NLG)
Shielded Consoles
Cowlings, Nacelles,
Thrust Reverser Doors
Engine Handling
Wing Structures
Fairings & Panels
Floor Structures
Control Surfaces
Stairs
Radomes
Fuselage Structures
Winglets
Company Restricted
Transportation
Handling / Lifting
Moveable Systems
Containerisation
Maintenance
Doors
Engine Inlet
Screens
Tunnel Covers
Rotor Blades
Ramps
Sponsons
Floors
Pylons
Cockpits
Cabin Interiors
Shaft Couplings
Transition/Boom
Fuselage Structures
Kaman Aerospace Group Aircraft Product Portfolio – Rotorcraft
Company Restricted
Company Restricted
Tooling Design & Manufacture
Civil & Military Aircraft Platforms:
Fixed Wing - Rotary & Space Applications.
Tooling & Composite Specialists:
•Project Management
•Turnkey Solutions
•Composite panel mould & trim tooling:
(Invar – Steel – Aluminium – Nickel – CFC – GRP)
•Large 3 & 5 axis CNC machining capability
•Assembly jigs inc complex mechanised assembly fixtures
•Ground Support Equipment
•Tool Installation
•Tool try out - component / process proving
•Concurrent & reverse engineering
•Engineering consultancy & tooling support worldwide
Truly Global – One KAMAN
KAMAN Tooling is a centre of excellence for:
Aerospace Tool Design - Manufacture - Installation
Consisting of a large highly skilled multi-disciplined team,
supporting major primes and tier 1 & 2 customers on some of the most
advanced aircraft projects in development and production.
Complex assembly tooling, with integrated automation systems, including:
- Moving
- Turning
- Hydraulic / Pneumatic / Electric
- Vacuum Assist
- Laser Positioning Systems
Sub and Final Assembly Jigs, including laser positioning and AGV compatibility
Test Fixtures / Rigs
Complex Satellite Test Fixtures
Complete service including tool installation and through life cycle maintenance
CATIA V4 - V5 & Unigraphics
Secure FTP Protocols
STEP and IGES Translators
RTM (Real Time Machining)
CE Marking & Technical Files
Operator User Manuals
Concurrent & Reverse Engineering
In-house Design & Project Management
Company Restricted
• MRP Managed
• MS Project
• RAG Reports
• SWIP Reports
• Five Box Reporting
Project Managers (4)
International experienced
KAMAN has over 22 yrs experience in the
Design and Manufacture of aircraft tooling:
Nacelle Repair Jig
Embraer KC-390 Cargo Ramp
KAMAN have been contracted to design and manufacture the cargo ramp production
assembly line, and provide Installation at the customers manufacturing facility
20 tool package consisting:
Assembly tooling
Transportation trolleys
Lifting frames
Onsite Installation
Company Restricted
The assembly line has been developed to operate as a pulse line,
in order to maximise build efficiency and encourage reduced takt time,
while creating an ergonomically safe operator environment
Automation Concept
Kaman Tooling were commissioned to design this conceptual robotic
drill and countersinking cell, working to a high volume pulse line
configuration with a minimal takt time requirement,
Universal palletised handling system
Vacuum assisted holding fixtures
Vision Cam alignment
Lifting frames
Company Restricted
Drill & Countersink - Robotic cell
2013:
5m x 2.5m x 1.25m
Q4: 2013
KTL will be increasing our machine capability up to 20m x 3m x 1.5m
Company Restricted
3 & 5 Axis CNC Machining
Airbus A350
(FLE)
Bird Strike
Test Piece - Mould & Impact Fixture
6m x 2.3m x 1.5m
Onsite access to 6 autoclaves: (largest - 13m x 3.125m)
Enabling full customer support:
- New Product Introduction (NPI)
- Process Development
Use of Helium Leak Detect System to certify and guarantee the
integrity of the mould surface:
- Nickel Shell
- Carbon Fibre
- Invar
- Steel
- Aluminium
- Tooling Board
- Medium Density Fibre Board
Mould Tooling
Airbus A380
GLARE Test tool
(5m x 3m x 1m)
2.5m x 2.5m x 1m Airbus A350:
FLE: (8m x 1m x 1m)
Company Restricted
Rout Tooling
Company Restricted
Airbus - Atlas
Wing / Root Fairing
Turnover Rout Fixture
5 Axis - Fully Sensored
KAMAN have manufactured a large range of rout tooling,
From simple bench hand rout fixtures, to complex 5 Axis tools comprising of integrated
sensors and vacuum cups, along with indexed sub-frames using Wixroyd type locators to
enable the accurate repeatability of operations in a pulse line environment of high volume
critical finish manufacturing,
Various materials used:
- Glass Reinforced Plastics
- Pre-Preg / Carbon Fibre
- Tooling Board
- Aluminium
Learjet 85
Multiple Loading Fixture
Learjet 85
Vacuum Drill & Rout
Airbus - A350
FLE- Rout Fixture
Multi-million tooling budget
Full project management
Design & make detail tooling, Sub-assembly
& Main assembly fixtures
Laser tracker & Installation of all tooling in
clean room conditions
Thru production calibration support
E3000 Satellite Project
Company Restricted
Satellite Test Equipment (Integrated laser positioning system)
AIRBUS - A350 (FLE):
Automated Drill-C’sk & Assembly Jigs
A350 (FLE) Mid – Outboard Spars
Complete Design by ASSYSTEM
Each moveable work station is 8m x 3m x 2m
Air Guided Vehicle Compatible
Build to Print complete at KAMAN
Full onsite support and tool Installation
Company Restricted
AIRBUS - A350 (FLE):
Automated Drill-C’sk & Assembly Jigs
Company Restricted
A350 (FLE) Inboard Spars
Complete Design by ASSYSTEM
Each moveable work station is 8m x 3m x 2m
Air Guided Vehicle Compatible
Build to Print complete at KAMAN
Full onsite support and tool Installation
Design partner
Manufactured in 8m modules (42m complete)
Delivered & Installed onsite at Airbus Broughton by our tool installation team
AIRBUS - A380
Wing Skin Shot Peen Fixtures
Company Restricted
Ground Support Equipment
Company Restricted
GSE is a core part of Kaman Tooling’s business portfolio:
Bae Systems being our prime customer, KAMAN also manufacture bespoke:
Lifting, Transportation and Handling solutions for - Hydro (DE), Rolls Royce and Spirit AeroSystems,
Outboard Sensor
Protection
Canopy Stays
Landing Gear Locks
Canopy
Transportation
Protective Covers
Engine Handling
Eurofighter
Tornado
Hawk
Rolls Royce Trent 1000
Airbus A380
Bell AH-1Z
GSE: Handling Equipment – Engine & Airframe
Company Restricted
Trent XWB: Airbus A350
Nacelle Handling
Build to print
Proof loading certified
Welding certified
CE Marked
Operator user manuals
GSE: Handling Equipment – Engine & Airframe
Company Restricted Eurofighter
Front Fuselage Transportation Stillage
GSE: Lifting Equipment
Company Restricted
Vacuum Assist Lifting
In house design – Build to print
Proof loading certified
CE Marked
Operator user manuals
ISO 14001
Company Restricted
(12m x 2.5m x 4m)
AIRBUS A380: IOFLE Transportation Trailer
Build to Print
Full project management.
Fabricated in house
GSE: Vac Formed & Rubber Covers
Company Restricted
All our GSE is designed and manufactured onsite to meet our customers expectations,
with all models & moulds made by our specialist patternmakers, and with final production
and kitting taking place in our dedicated cell.
Out–Board Sensors
Air Intakes
Internal Switches (Cockpit)
GSE: Kitting & Support Equipment inc Containerisation
Company Restricted
Flight Line Maintenance and Specialist Tooling:
Canopy Struts
Engine Bay Door Struts Canopy Transportation Single or
Twin
Fin Installation & Removal
Canopy Rigging Pins
Actuator
Installation & Removal
Kaman Tooling is an ITAR approved company, and have long been involved in the design and manufacture of various
tooling packages in support of F35 Development & Production including all the In Flight Opening Doors - composite mould
and assembly:
Bae Systems (UK): for Lockheed Martin (Single Source Supplier - All Mould Tools)
Rear Fuselage - HTP - VTP
Invar Mould Tools,
Vacuum Router Tools
Bonding Fixtures
Final assembly Fixtures
Lifting Equipment
TERMA AS (Denmark) / Northrop Grumman:
Gun Pod Mandrel Tool
Invar Mould Tools,
Vacuum Router Tools
Bonding Fixtures
Final assembly Fixtures
Fokker Aerostructures (Netherlands):
All In Flight Opening Doors : CTOL - STVOL - CV
Invar Mould Tools,
Vacuum Router Tools
Bonding Fixtures
Final assembly Fixtures
EDM Ltd (United Kingdom):
Full scale (Replica) working doors – Training solutions
F-35: KAMAN Involvement
Company Restricted No Tooling pictures are available due to ITAR Restrictions:
C D F
G
B
A H
E
A. Lift Fan Upper
B. Auxiliary Air Intake
C. Lift Fan Exhaust
D. Roll Nozzle Ducts
E. Main Landing Gear
F. Lift Fan Lower
G. Nose Landing gear
H. In Flight Re-Fuelling
Company Restricted
AIRBUS - A320/321 (Rate Tooling):
Nickel & Composite Moulds
Project awarded to KAMAN as the preferred supplier having manufactured the previous
5 sets of 44 mould tools, consisting: 32 Carbon Fibre & 12 Nickel Shell mould tools,
Fairings - Under & Over wing panels
Build to Print
Full project management.
All models, stage tooling etc re-furbished in-house, along with final production tooling
Onsite support (Malaysia)
KTL designed and developed the full suite of tooling for component
manufacture and final assembly along with developing manufacturing
processes in support of Kaman Composites.
Bombardier LJ85 PAX & OWEE Doors
Main Passenger
Entry/Exit Door
Company Restricted
Over Wing Emergency
Exit Door
Bell Helicopter AH-1Z Cabin
Kaman Tooling was responsible for the:
- Full In-house Design & Manufacture
FWD Fuselage & Pylon Production Tooling
137 Production Tools
12 Major Assembly Jigs inc Splice Fixtures
Onsite Installation KAMAN (Jacksonville FL)
Company Restricted
Canopy
Assembly Jig
Pylon Assembly
Breakout Fixture
This suite of tooling was manufactured in our UK facility - shipped to Jacksonville (USA), where it
was fully assembled and calibrated by our tool installation team prior to customer buy off
Aft Fuse
Assembly Jig
Kaman Tooling was responsible for the In-house Design and Manufacture of
the wing assembly jigs and fixtures for the flight control surfaces and the
onsite Installation at KAMAN (Jacksonville FL)
Leading Edge Assembly Jig (Port/STB)
BRG Install Assy Jigs (INBD / OUTBD)
LE Stage 1 Assy Fixture (Port/STB)
LE Stage 2 RMF Fixture (Port/STB)
LE Stage 3 Assy/ Checking Fixture (Port/STB)
Boeing A-10 Re-Wing
Company Restricted No Tooling pictures are available due to ITAR Restrictions:
This suite of tooling was manufactured in our UK facility - shipped to Jacksonville (USA), where it
was fully assembled and calibrated by our tool installation team prior to customer buy off
Gulfstream G280: Winglets
Kaman Tooling was responsible for the In-house
Design and Manufacture of the:
Mould tools (L/R)
5 Axis rout fixtures (L/R)
Sub & Final Assembly jig (L/R)
CMM Checking fixture (L/R)
Test Fixture (L/R)
The Winglet is a co-cure /co-bonded assembly consisting of several
individual carbon parts, Inner and Outer skins with a NOMEX
honeycomb core and manufactured in-house by KAMAN.
The Winglets are also capped with a protective polished Aluminum
leading edge
Company Restricted
Method 1 Approval (Direct to Line Delivery)
Company Restricted
Key Processes & Summary:
Design & Engineering
Project Management
Fabrication
Machining
Composite Manufacture
Assembly
Inspection
We have the ability to:
Concept / Design bespoke tooling solutions,
Develop and implement the required engineering processes,
Project Manage, reporting directly to all stakeholders,
Provide CE Marking - Technical User Manuals, and a fully
validated CMM Inspection report,
ISO 18001
ISO14001
AS EN 9100
BS EN 9001:2000
Company Restricted
KAMAN Tooling Strategy
Kaman are actively looking to increase it’s USA tool manufacturing presence and capability, where we currently
have two small footprints that service and maintain KAMAN’s own internal requirements,
KAMAN Bloomsfield CT: Tool maintenance in support of the K-Max, and various aerostructures assembly programs,
KAMAN Wichita : Mould tool maintenance in support of composite component / structural manufacturing,
The three major considerations are:
Invest in either or both the above facilities, and develop them up to the UK standard and capabilities,
Start a new company (KAMAN Tooling USA), potentially in our KAMAN Jacksonville - Whittaker Road facility
In the UK, we have now out grown our current Darwen facility, and have secured significant CAPEX funding from
KAMAN Corporate,
This will be used to open a second (60,000 sq/ft) facility, which will become operational during Q2 2013,
and also see the introduction of our newly ordered Correa Nayak 5 Axis CNC machine (20m), in Q4 2013,
This new facility will be dedicated to:
3 & 5 axis CNC machining,
Major jig & fixture assemblies.
Large mould tools
(Artists Impression)
Andrew Rourke - Sales & Marketing Manager
Tel: 00 44 (0)1254 874 977
Mobile: 00 44 (0) 7912 540370
E-mail: [email protected]
KAMAN Tooling Ltd
India Mill, Darwen
Lancashire
BB3 1AD
United Kingdom
