Tooling Ltd

Jerry RICkeft$ Oi,,"'" Pr .... " ~.ion Prod",,"

KAMAN ". 'FT

SPlH:kalty Be.rlngs & Englnf!(lre

Fuzing & Precis ion Product s

1. Middletown, CT 2. Orlando, F\. 3. Tucson, AZ

KAMAN ". 'FT'

Sj)eckalty Be~g5 & Englne.:ucd Pfoducts

4. Bloomfield, CT 5. Dach,bech, DE

Air Vehicles & MRO

6. Bloomfield, CT

Composlle SlruClures

7. Bloomfield, CT 8. Wichita , KS 9. lancashire, UK 10. Bennington, VT 11 . Goa , India

Engineering Services

12. Everett , WA

Metallic's & Assembly

13. Jacksonville, FL 14. Chihuahua, Mexico

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Transportatio n Handlilg l LWt ing Moveable Systems Contailerisation Mailtenance

Floor Structures

Shielded Consoles Fairings & Panels

Cowlings, Nacelles, Thrust Reverser Doors Engine Handling

Wing Structures

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Kaman Aerospace Group Aircraft Product Portfolio - Fixed Wing

000 rs ~I"C ""'O" tUl) Winglets

Radomes

Fuselage Structures

Control Surfaces

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Engine Inlet Screens .... ,

T ransilion/Boom

Ramps

Cabin Interiors

Fuselage Structures

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Shaft Couplings

Tunnel Covers Rolor Blades

CockpilS

Pylons Sponsons

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KAMAN Tooling is a centre of excellence for:

Aerospace Tool Design Manufacture Installation

Consisting of a large highly skiled multidisciplined team, supporting major prmes and tier 1 & 2 customers on some of the most advanced aircraft projects in development and production.

Tooling & Composite Specialists:

-Project Management -

-Turnkey Solutions -Composite panel mould & trim looling:

(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

Civit & Military Aircraft Platforms: Fixed Wing - Rotary & Space Applications.

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KAMAN has over 22 yrs experience In the Design and Manufacture 01 aircraft tooling :

CATIA V4 . V5 & Unigraphics Secure RP Protocols STEP and IGES Translators RTM (Real Tme Machining) CE Marking & TedmicaJ Files Operator User Manuals Concurrent & Reverse Engineering

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 Salel~te Test Fixtures

Complete service including tool Installation and through life cycle maintenance

KAMAN - ...

PrO/e

KAMAN have been contracted to design and manufacture the cargo ramp production assembly line, and provide Instalation at the customers manufacturing faci~ty

201001 packagecoosisting :

Assembly tooling Transportation trolleys lifting frames Onsile Installation

The assembly line has been developed to operate as a pulse ~ne, in Ofoor to maximise bu ikj efficiency and encourage reduced takt time, wIlile creating an ergonomically safe operatOf environment

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Drill & Countersink Robotic cell

Kaman Too~ng were commissioned to design this conceptual robotic dril and countersinking cell, working 10 a high volume pulse line configuration with a minimatlakllime requirement,

Universal paletised handling system Vacuum assisted holding fixtures Vision Cam alignment Lift ing frames

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Automation Concept

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2013: 5m x 2.5m x 1.25m

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04: 2013 KTl wi" be increasing OIJ" machine capability up 10 20m x 3m x 105m

Alrbu. AlSO (FLE)

Bird Strille Test Pieee " Mould & Impact Fixture

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2.5mx 2.5m x 1m

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Onsite access to 6 autodaves: (largest - 13m x 3.125m) Enabling full aJstomer support:

New Producllnlroduclion (NPI) Process Development

Use 01 Helium Leak Deled System to certify and guarantee the integrity of the mouk::l surface:

Nickel Shell Carbon Fibre Invar Steel Aluminium Tooling Board Medium Density Fibre Board

A~bl.ll A3SO GLARE Tesl 100l (5m.Sm.lm)

I .... , Al50: FlE: (8m .lm x 1m)

5 Axis - Fully Sensored

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KAMAN have manufactured a large range of rout tooling:,

From simple bench hand rout fixhJres, to complex 5 Axis tools comprising of integrated sensors and vacuum cups, along: with indexed sub-frames uSllg Wixroyd type locators to enable the aca.nate repeatability of operations in a pulse line environment of high volume critical fllish manufacturing:,

Va,lova m.lerlals used:

- Glass Reinlorced Plastics - Pre-Preg I Carbon Rbre - Tool ing Board - Aluminium

AIrbus - Atlas Wing / ROOI Fairing

TurnoYer Roul Fixture

Learjel85 Vacuum Onll & RaJt

Airbus - AlSO Fle- Rout FIXture

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Multi-milMon tooling budget

Full project management Design & make detail tooling , Sub-assembly & Main assembly fixtures

Laser tracker & Installation of alil00lin9 in dean room conditions

Thru production caMbral ion support

Satellite T .. t Equipment ("'I0I;l"'" __ pcIOI"""1"Q 11"_1 KAMAN ", 'FT-

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A3SO (FLE) Mid - Outboard Spars Complete Design by ASSVSTEM Eadl moveable work slalion is 8m x 3m x 2m Air Guided Vehicle Compatible Build to Pril l complele al KAMAN Full onsile suppor1 and tool Installation

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A350 (FLE) Inboard Spars Complete Design by ASSVSTEM Each moveable work slation is &n x 3m x 2m Air Guided Vehicle Compalible Build to Print complele al KAMAN Full ensUe suppor1 and loollnslallatien

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Design partner Manufactured in 8m modules (42m complete) Delivered & Installed onsite at Airbus Broughton by our tool installation team

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GSE is a core part of Kaman Tooling's business portfolio:

Bae Systems being our prime customer, KAMAN also maJlufacture bespoke: Ufting , TraJlsportation and Handling solutions for - Hydro (DE), Rolls Royce and Spirit AeroSystems,

Transportation

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Outboard Sensor Protection

Canopy Stays Eurofighter Tornado Hawk

Landing Gear Locks

Rolls Royce Trent 1000 Airbus AlSO Sell AH.1Z

BlE SYSTEMS G AIRBUS iii

~~ ----SPIAI~ ..... ' ... -.

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Trent XW 8 : Airbus AlSO Nacele Hand~ng

Build 10 prlnl

Proof loading C(!rtd;oo Weld ing C(!rtrt;oo CE Marked Operator user manuals

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Eutolig hte t .... f rOnl f uselage TransportatOl Stillage C' " iJR __

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In house design - Build to print

Proot loading certi lied CEMarked Operator user manu~ 15014001

Vacuum Ass;Sllifl ing

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Buikj to Print Ful project management Fabricated in house

( 12m~2 "Smx4m)

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All our GSE is designed and manulactured ons~e to meet our customers expectations, w~h all models & moulds made by our specialist patternmakers, and with linal production and killing taking place in our dedicated eel.

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Out-8oard Sensors Air Intakes Intemal Switches (Cockpit)

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Canopy Transportation SIngle or

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Canopy Rlgglnll Pins

Actuator Installation & Remoyal

Equipment,~ Containerisation

Flight Line Maintenance and Specialist Tooling :

Canopy Slruts

Engine Bay Door Slruls

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F-3S: KAMAN Involvement

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 includl19 all the In Right Opening Doors - composite mould and assembly:

Bae Systems (UK): lor Lockheed Martin ~ScuICSuwJiM AI_ T~I Bear Fuselage. tfTP VTP " Invar Mould Tools, ' Vacuum Router Tools "Bonding FixlUres "Filal assembly FixlUres ' Lifting Equipment

TERMAAS (Denmark) I Northrop Grumman: Gun Pod Mandrel Tool " Invar Mould Tools, ' Vacuum Router Tools " Sonding Fixtures "Final assembly Fixtures

Fokker Aerostructures (Netherlands) : All In Flight Ooonjnq Doors : CroL - STVOL - CV

"Invar MouldTools, ' Vacuum Aouter Tools ' Bonding Fixtures "Final assembly Filctures

EDM ltd (United Kingdom) : " Full scale (Replica) working doors - Training solutions

KAMAN

A. Lift FJIIl Upper Au~lIl.ry Air Intake C. Lift Ftn Exh.ust D. Ro ll Nozzle Ductl E. M.ln Llndlng Ge.r ,. Lift FM Lower G. NoM L.ndlng gear ,. In Flight R .. FUll lllng

"a aF r No Tooflng pictures are available due to ITAR Restrictions:

BAE SYSIEMS

TERMA'" FOKKER

AUO$UUOU.U

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Project awarded to KAMAN as the preferred supplier having manufactured the previous 5 sets of 44 mould tools, consisting: 32 Carbon Fbre & 12 Nickel Shell mould tools,

Fai"ings ' Under & Over wing panels

Build to Print

Ful project management All models , stage tooli"lg etc re -furbished in-house , along with !i"lal production tooling

' Onsite support (Malaysia)

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Main Passenger Entry/Ed Door

Over Wing Emergency Exit Door

KTL designed and developed the l ull suite of tooling for component manufacture and final assembly along with developing manufacturing processes in support 01 Kaman Composites.

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Kaman Tooling was responsible for the:

- Fullln.flouse Design & ManufacllHe

FWD Fuselage & Pylon Production Tooling

137 Production Tools 12 Ma;::,r Assembly Jigs r.c Splice Fixtures Onsile Installalion KAMAN (Jacksonville Fl )

AM Fuse AssembtyJig Pjion Assembty

Breakoul Fixlure

eo""" Assembly Jig

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Kaman Tooling was respoosible for the In-house Design and Manufacture of the wilg assembly jigs and fixtures for the flight cootrol surfaces and the onsite Installatioo at KAMAN (Jacksooville FL)

Leading Edge Assembly Jig (PortJSTB) BAG Install Assy Jigs (INBD / OUTBD) LE Stage I Assy Fixture (PortlSTB) LE Stage 2 RMF Fixture (PortISTB) LE Stage 3 Assy/ Checking Fixture (PortlSTB)

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Kaman Tooling was responsible for the In-house Design and Manufacture of the:

Moukl tools (~ 5 Axis rout fixtures (URI Sub & Final Assembly jig (~ CMM Checking fixture (~ Test Fixture (URI

The Winglel is a co-cure Ico-bonded assembly consis ting 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 w~h a protective polished Aluminum leading edge

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Design & Engineering Project Management Fabrication Madlining Composite Manufacture Assembly Inspec~on

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We have the ab ili ty to :

Concept I Design bespoke tooling solutions, Develop and implement the required engineering processes, Project Manage , reporting direelly to al stakeholders , Provide CE Marking - Tedmical User Manuals , and a fully

validated CMM Inspection report,

IU SYSTEIS Method 1 Approval (Direct to LI .... Delivery)

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' .. ISO 18001 - --

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Kaman are actively looking to increase it's USA tool manufacturing presence and capab~ity, where we currently :::::::: have two small footPl'ints that service and maintain KAMAN's own interllBl requirements,

KAMAN Bloomsfield CT: Tool maintenance in support of the K Max , and various aerosb'uctures assembly Pl'ograms,

KAMAN Wichita : Mould tool maintenance in support of composite component I structural manufacturing,

The three major considerations are:

Invest in either Of both /he above faciities , and develop them up to the UK standard and capabiities,

Start a new company (KAMAN Tooling USA), potentia/ly in our KAMAN Jacksonville . Whittaker Road facitty

In the UK, we have now out grown our current Darwen faci~ty, and have secured signil icant CAPEX funding Irom KAMAN Corporate,

This wi. be used to open a second (60,000 sqlft) fadity, 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 ,g & fbcture assemb~es, Large mould tools

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KAMAN KAMAN CompoSI1es - UK lid Aerospace

BAE SYSTEMS

THALES ~' 'CDGe"DD' CASSIDIAN

ASTRIUM " . - . ~ AgustaWestiand ............ c ..... .,

I Rolls-Royce' ---

GE AvlOtIOn

CTItM

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KAMAN Fabocaled Products Ltd

a Airc.lI. ~ !AI,"" ""'"' MBIlA

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Goo FOKKER

AUOSTiltuCTURES

BRITISH AIRWAYS

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KAMAN Aerospace

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