Kaman Aerospace Group is a global aerospace and defense company that designs and manufactures aircraft structures, components, and tooling. It has 4,800 employees across 13 countries, annual sales of $1.6 billion, and headquarters in Bloomfield, Connecticut. Kaman provides products and services for both civilian and military aerospace applications, including fixed wing aircraft, rotary wing aircraft, and space applications.

1. (Artists Impression)
ONE KAMAN - Truly Global
 Civilian & Military Aerospace
 Fixed Wing - Rotary
 Space Applications

2. 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

3. Kaman Aerospace Worldwide Locations
HelicoptersPrecision 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
AerosystemsEngineered 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

4. 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
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Transportation:
 Handling / Lifting
 Moveable Systems
 Containerisation
 Maintenance

5. 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

6. 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 customers on some of the most
advanced aircraft projects in development and production.
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Tooling Design & Manufacture
Tooling & Composite Specialists:
 Project Management
 Turnkey solutions, concurrent & reverse engineering
 Composite panel mould & trim tooling
 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
 Engineering consultancy & tooling support worldwide
Kaman is committed to Continuous Improvement,
Lean Enterprise and Cost Reduction Initiatives,
a few of these are described below:
 Lean Enterprise/Kaizen events
 “5’s”
 Set-up reduction,
 Optimised material and process flows
 Total Preventive Maintenance (TPM)
 Implementation of Visual Workspace Management
 Utilisation of advanced CNC equipment and techniques

7.  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
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KAMAN has over 22 yrs experience in the Design and Manufacture of aircraft tooling:
GE90 Nacelle Repair Jig
Project Management
KAMAN Tooling Ltd have four Internationally experienced Project Managers, utilising Microsoft Project,
along with other various methods of reporting such as:
Five Box Reporting, RAG and SWIP Reports,
In order to support weekly project reviews with our customers outside of the UK, we also have:
Video conferencing
WEBEX capabilities

8. Past, Present & Commitment
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Examples of past and present programs include:
 Embraer KC-390: Cargo Ramp Assembly line
 Airbus A350: Fixed Leading Edge Mould Tools (Nickel Shell), Bird Strike Test Tooling,
Assembly Tools to facilitate Automation (Drilling & Riveting) – AGV Movement
 Airbus A380: Wing skin Automated Shot Peen Fixtures
 Airbus A320 – NEO: Fairings, Over & Under Wing Panels – Nickel Shell / Composite Moulds
CFM International LEAP-X (Nacelle Panels)
 Airbus (UK): Next Generation Composite Wing Development Tooling
 EADS Astrium: Satellite Assembly , Ground Test Equipment & GSE
 Bombardier C-Series: Composite Wing Tooling
 Lockheed Martin F35: Assembly Jigs, IFOD (Doors) ,Fuselage and Tail Plane
 Bombardier Learjet 85: Main Cabin & Over Wing Emergency Exit Door , Component & Assembly Tooling
 Bae Typhoon / Taranis: Assembly Jigs, Mould Tools (Invar – Nickel)
 Gulf Stream G280: Winglet & Aileron Final Assembly Jigs
 Rolls Royce A350 XWB: C-Frame Nacelle Handling Fixtures
 KAMAN/Boeing A-10: Assembly - Wing Fatigue Upgrade Program)
 Bell-Viper AH-1Z: Forward - Aft - Splice & Pylon Assembly Tooling
 UK MoD: Engine Strip & Survey, Ground Support Equipment (Eurofighter, Tornado & Hawk)

9. 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
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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

10. 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

11. 2013:
5m x 2.5m x 1.25m
Q4: 2013: Will see an increase in our 5 axis capability
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

12.  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

13. Rout Tooling
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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

14.  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
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Satellite Test Equipment
(Integrated laser positioning system)

15.  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
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16. AIRBUS - A350 (FLE):
Automated Drill-C’sk & Assembly Jigs
A350 (FLE) Mid – Outboard Spars
 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

17. AIRBUS - A350 (FLE):
Automated Drill-C’sk & Assembly Jigs
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A350 (FLE) Inboard Spars
 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

18. 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 RestrictedNo 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

19. 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
 Handling solutions
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

20. GSE: Handling Equipment – Engine & Airframe
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Trent XWB: Airbus A350
Nacelle Handling
Build to print:
 Proof loading certified
 Welding certified
 CE Marked
 Operator user manuals

21. GSE: Handling Equipment – Engine & Airframe
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Eurofighter
Front Fuselage Transportation Stillage

22. GSE: Lifting Equipment
Company Restricted
Vacuum Assist Lifting
In house design – Build to print
 Proof loading certified
 CE Marked
 Operator user manuals
 ISO 14001

23. Company Restricted
(12m x 2.5m x 4m)
AIRBUS A380: IOFLE Transportation Trailer
 Build to Print
 Full project management.
 Fabricated in house

24. GSE: Vac Formed & Rubber Covers
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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)

25. GSE: Kitting & Support Equipment inc Containerisation
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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

26. 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)

27. 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
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Over Wing Emergency
Exit Door

28. 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

29. 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

30. 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
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31. Method 1 Approval (Direct to Line Delivery)
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Key Processes & Summary:
 Design & Engineering
 Project Management
 Fabrication (inc Coded)
 3 & 5 Axis Machining
 Composite Manufacture
 Assembly
 Inspection
ISO 18001
ISO14001
AS EN 9100
BS EN 9001:2000
Kaman’s Unsurpassed Product Quality
Kaman has a comprehensive Quality Management System that is fully compliant with the standards and
specifications identified below, designed to ensure systematic controls are in place to guarantee
customer quality requirements are consistently met.
 AS EN9100 Rev C Quality Management
 ISO 14001 Environmental Management
 ISO 18001 Health & Safety Management
The aforementioned certifications are a testament to the integrity of our systems and procedures and our
ability to provide aerospace tooling of the highest quality. Kaman’s Quality Assurance organisation, in conjunction with
our Manufacturing Engineering, Operations, Purchasing, and the other functional organisations, constitutes a
vital and effective team to ensure that our customers are provided with the optimum in product quality,
integrity, timely delivery, and continued customer support.

32. Company Restricted
KAMAN Tooling Investment Strategy
(Artists Impression)HEXAGON Delta Slant: 6.3m
CORREA Anayak: 20m x 3m x 1.5m
Having recognised the changing requirements in aircraft design - manufacturing and assembly processes,
we have now committed to some significant capital investments in order to allow us to adapt, to meet,
and have the capability and capacity exceed these future challenges,
We have approached this by committing to a second 60,000sq/ft facility located within the new
Aerospace Supply Park in Burnley (UK), and by procuring additional new equipment including:
 20m 5axis Correa Anayak CNC machine
 6.3m Hexagon Delta Slant CMM
This investment is further testament to the continued support and belief in KAMAN Tooling Ltd
by the board of KAMAN Corporation and underpins our strategy of growth and increased capabilities,

33. Major Client List:
Company Restricted

34. Andrew Rourke - Sales & Marketing Manager
Tel: 00 44 (0)1254 874 977
Mobile: 00 44 (0) 7912 540370
E-mail: Andrew.Rourke@kaman.com
KAMAN Tooling Ltd
India Mill, Darwen
Lancashire
BB3 1AD
United Kingdom
Please visit us at:
Hall 3 – Stand D118