Tooling Ltd

KAMAN
Aerospace
Greg Steiner
President

Aerosystems
.1m Uirwood
Presioont

Composite
Structures

SPlH:kalty Be.rlngs
& Englnf!(lre<i Product.

Jerry RICkeft$

Oi,,"'" Pr.... "

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KAMAN
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Rob PlI.,..on
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Spec.11y

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Bob Manaskle

AI L.'v'ete

G.norlll MIn.r

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Annual Sales 51.6 BN

4,800 Employees
Headquarters: Bloomfield, Connecticut
listed on NYSE: KAMN

Metall ic's &

Assembl y

Cliff Ward
VPIOo_1II r.troog.

Bob IUnasllle

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Fuzing &
Precis io n Prod uct s
1. Middletown, CT
2. Orlando, F\.
3. Tucson, AZ

KAMAN
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Sj)eckalty

Be~g5

& Englne.:ucd Pfoducts

4. Bloomfield, CT

5. Dach,bech, DE

Air Vehi cles

& MRO
6. Bloomfield, CT

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

Engineering
Service s
12. Everett , WA

Metallic's &
Assembly
13. Jacksonville, FL
14. Chihuahua , Mexico

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Kaman Aerospace Group

Aircraft Product Portfolio - Fixed Wing
Transportati o n
Handlilg l LWting
Moveable Systems

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

Winglets

Contailerisation
Mailtenance

Radomes
Fuselage Structures

Floor Structures

Shielded Consoles
Fairings & Panels

Cowlings, Nacelles,
Thrust Reverser Doors
Engine Handling
Wing Structures

Control Surfaces

KAMAN
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Engine Inlet
Screens ....,

Shaft Couplings
Tunnel Covers
Rolor Blades

Transilion/Boom

Ramps
CockpilS
Cabin Interiors

Fuselage Structures

Pylons
Sponsons

KAMAN
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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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Truly Global - One KAMAN

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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

PrO/e<:1 Mana ger, (4 )

Inlem .donal experienced

MRP Managed
MS Project
RAG Reports
SWIP Reports
Five Box Reporting

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

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KAMAN

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

201001 packagecoosisting :

Assembly tooling
Transportation trolleys
lifting frames
Onsile Installation

The assemb ly line has been developed to operate as a p ulse ~n e,

in Ofoor to maximise bu ikj efficiency and encourage reduced takt time,
wIlile creating an ergonomically safe operatOf environment

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Automation Concept

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
Lifting fram es

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Alrb u. AlSO
(FLE)
Bird Strille
Test Pieee " Mould & Impact Fixture

2013 :
5m x 2.5m x 1.25m

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04 : 2013
machine capability up 10 20m x 3m x 105m

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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:
2.5mx 2.5m x 1m

FlE: (8m .lm x 1m)

Nickel Shell
Carbon Fibre

Invar
Steel

Aluminium
Tooling Board
Medium Density Fibre Board

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

KAMAN
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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

- Tooling Board
- Aluminium
Learjel85
Vacuum Onll & RaJt

5 Axis - Fully Sensored

KAMAN
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AIrbus - Atlas
Wing / ROOI Fairing
TurnoYer Roul Fixture

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 produc tion caMbra lion support

Satellite T..t Equ ipment

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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 Prill 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 com plete)
Delivered & Installed onsite at Airbus Broughton by our tool installation team

KAMAN
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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 AeroS ystems,

Transportation

Outboard Sensor
Protection

BlE SYSTEMS
Landing Gear Locks

Canopy Stays

KAMAN
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Eurofighter
To rnado
Hawk
Rolls Royce Trent 1000
Airbus AlSO
Sell AH.1Z

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Trent XW 8 : Airbu s AlSO

Nacele

Ha nd ~ng

Build 10 prlnl
Proof load ing C(!rtd;oo
Weld ing C(!rtrt;oo
CE Marked

Operator user manua ls

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f rOnl f uselage TransportatOl Stillage

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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)

KAMAN
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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.

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

KAMAN
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BIE SYSTEMS
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Equipment,~

Containerisation

Flight Line Maintenance and Specialist Tooling :

Canopy Rlgglnll Pins

Canopy Slruts

Canopy Transportation SIngle or

KAMAN
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Eng ine Bay Door Slruls

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Actuator
Installation & Remoyal

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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) :

A ll In Flight Ooonjnq Doors : CroL - STVOL - CV

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BAE SYSIEMS

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Lift FJIIl Upper

Au~lIl.ry Air Intake
Lift Ftn Exh.ust
Ro ll Nozzle Ductl
M.ln Llndlng Ge.r
Lift FM Lower

G.

NoM L.ndlng gear

FOKKER

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

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In Flight R.. FUll lllng

TERMA'"
AUO$UUOU.U

EDM ltd (United Kingdom) :

" Full scale (Replica) working doors - Training solutions

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No Tooflng pictures are available due to ITAR Restrictions:

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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
manu facture and final assembly along with d eveloping manufacturing
processes in support 01 Kaman Composites.

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Kaman Tooling was responsible for the:

- Fullln.flouse Design & ManufacllHe
FWD Fuselage & Pyl on Producti on 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

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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)

Lea ding 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)

nNI.uoll:>Of<V MSII7.-zlIl<2l_" <XI UK 1 - '1 - ~ ",.n _ _ I ~ ..._

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No Tooflng pictures are avaHabfe due to ITAR Restrictions:

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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 KA MAN ,
The Winglets are also capped w~h a protective polished Al uminum
leading edge

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Design & Engineering

Project Management
Fabrication
Madlining
Composite Manufacture
Assembly
Inspec~on

We have the ab ility 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,

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ISO 18001
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IU SYSTEIS Method 1 Approval (Direct to LI.... Delivery)

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

we currently

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 signilicant CAPEX funding Irom
KAMAN Corporate,
This wi. be used to open a second (60,000 sqlft) fad ity, 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

Large mould tools

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KAMAN

KAMAN

KAMAN

CompoSI1es - UK lid

Aerospace

Fabocaled Products Ltd

a Airc.lI.

BAE SYSTEMS

THALES

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BRITISH AIRWAYS

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I Rolls-Royce'

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KAMAN
Aerospa ce

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