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DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
DJ Engineering Manufacturing pre
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DJ Engineering Manufacturing pre

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Aerospace Manufacturing and Parts Fabrication Services: …

Aerospace Manufacturing and Parts Fabrication Services:

• Precision Machining
• Large Assemblies
• Blue Streak/ AOG
• Composite Fabrication
• Various type of Metal hot-forming
• Titanium hot-forming
• Aluminum Extrusion up to 40' long
• Skins

Repair and Overhaul Services:

• Starter Generator Overhaul
• Landing Gears
• Wheels & Brakes
• Inlet and Nacelle system
• Components Repair and Overhaul
• Linear, Hydraulic, Flap, Door Actuators
• Flight Control Surfaces
• Airframe structural repair
• Advanced composite inspection and repair

Published in: Business
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Transcript

  • 1. www.djgrp.com Call 316-775-1212
  • 2. MANUFACTURING LEADER MRO SOLUTION 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). 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. COMPOSITES SERVICES Maintenance, Repair and Overhaul 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.
  • 3. •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. .
  • 4. Machine Facts Center Category 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 5-Axis PC 60/V 4,000 RPM PC 120/V 4,000 RPM 60" x 20" x 20" 120" x 50" x 36" 5-Axis SL-V50 Plus Waterjet 5-Axis Seramill 90° Head 4,000 RPM 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 146 315" x 93" x 39" 55" X 24" X 25"
  • 5. Machining/Milling 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. 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. Large Cargo Freighter Lower Fwd. Main Hinge Raw Material: Stainless Steel 15-5 PH Forging: Approx. 7000 lbs. Machined to 600 lbs. final product
  • 6. Machining/Milling 15-5 PH Stainless Steel Engine Mount. 50” Titanium Hog out 80” Long Hog out
  • 7. The Real Deal WIP
  • 8. Assemblies D-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.
  • 9. 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.
  • 10. Assemblies 100% of the parts for both projects were fabricated in house, using DJE owned resources exception to this rule being painting and NDT.
  • 11. Assemblies 100% of the parts for both projects were fabricated in house, using DJE owned resources exception to this rule being painting and NDT.
  • 12. 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
  • 13. DJ COMPOSITE Virtek LaserEdge Templating System 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 worksta­tions so ply layup on multiple parts can occur in parallel. Position Accuracy Short 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
  • 14. DJ COMPOSITE Composite Assembly  RJ Tail cone Assembly – wire  harness, antennae mount and  navigation light installation  Auxiliary Fuel Tank Assembly
  • 15. DJ COMPOSITE Composite Assembly  RJ Tail cone Assembly – wire  harness, antennae mount and  navigation light installation  Auxiliary Fuel Tank Assembly
  • 16. DJ COMPOSITE  Ducts (wash­out mandrels)  Complex Composite Structures  Laminates
  • 17. DJ COMPOSITE Composite Tool Design and Manufacture  Master Mould Machining  Graphite Epoxy Tool Manufacture  Construction of tooling aids
  • 18. DJ COMPOSITE Metal Bonding  Aluminum and Stainless Steel Bonded Panels
  • 19. DJ COMPOSITE Autoclave and Batch Oven  30’ x 10’ diameter Autoclave  Batch Oven Cure  Dual Daylight Press Cure
  • 20. DJ COMPOSITE Non-Destructive Testing  Real Time X­Ray  C­Scan and A­Scan  Microscopic Analysis
  • 21. Extrusion Solutions Aluminum 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.
  • 22. Custom Die Solutions 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.
  • 23. Extrusion Press Handling System 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
  • 24. Inspection & Quality assurance Our products fly. Quality is non-negotiable. As an ISO-9001 and AS 9100 certified supplier, we take pride in delivering only the best. If you have unique quality requirements, we will cooperate with your team to make certain that your standards become ours. Precision products require precision tools. We have two Coordinate Measurement Machines (CMM’s), four Laser Trackers, a hand-held optical laser scanner, hardness and conductivity meters.
  • 25. NDI/NDT CAPABILITIES and equipment • • • • • • • • Ultrasonic Inspection Through Transmission Pulse Echo C-Scan Eddy Current Magnetic Particle Dye Penetrant Conductivity Testing
  • 26. CONTACT D-J Engineering, Inc. 219 W. 6th Ave Augusta, KS 67010 Telephone: (316) 775-1212 Fax: (316) 775-4840 Visit us www.djgrp.com

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