Can Mastars manufacture custom aerospace components from my drawings?

Yes. Send your 3D CAD file and, where available, a 2D drawing with material, quantity, critical dimensions, tolerances, finish, and inspection requirements. Rough information is fine to start.

Do you support aerospace prototyping and aerospace contract manufacturing?

Yes. Mastars supports aerospace prototypes, engineering validation, pilot builds, low-volume manufacturing, and repeat production. The manufacturing route can change as the design matures.

Which manufacturing process should I use for my aerospace component?

It depends on geometry, material, quantity, and what you need to validate. CNC machining suits precise functional parts, 3D printing suits complex geometry and rapid iteration, while sheet metal, molding, or casting may be more practical for other geometries or production volumes.

What materials are available for aerospace components?

Common options include 6061 and 7075 aluminum, Grade 5 / Ti-6Al-4V titanium, 304 and 316 stainless steel, selected Inconel and nickel alloys, PEEK, PEI, PPS, and reinforced engineering plastics. Final selection depends on the process and project requirements.

What tolerances can you achieve on aerospace components?

For suitable CNC features, machining capability can reach ±0.005 mm. Actual tolerance depends on geometry, material, wall thickness, feature location, fixturing, thermal effects, finishing, and inspection access.

How should I evaluate an aerospace components manufacturer for quality?

Check the quality system, process capability, material control, inspection equipment, traceability, revision control, and documentation scope. Mastars supports ISO 9001-controlled manufacturing, incoming and in-process inspection, final inspection, CMM, FAI, and project-specific quality records.

Can you provide FAI and CMM inspection reports?

Yes, when required. Mastars can provide first article inspection, CMM measurement, dimensional reports, and agreed manufacturing records. Confirm any required reporting format, including AS9102, before production.

Do you provide material certificates and traceability?

Yes, when specified. Material certificates, CoC, lot traceability, and other required records can be defined before production. Documentation requirements may affect material sourcing, cost, and lead time.

Is Mastars AS9100 certified?

No. Mastars currently operates under ISO 9001:2015 and does not claim AS9100 certification. If AS9100, AS9102, NADCAP, or another aerospace-specific requirement is mandatory, include it in the RFQ before project acceptance.

Can you support low-volume or replacement aerospace parts?

Yes. CNC machining, additive manufacturing, sheet metal fabrication, and other processes can support prototypes, low-volume components, replacement parts, and legacy parts when drawings, samples, or usable design data are available.

Can a validated aerospace prototype go directly into production?

Not always. A prototype may confirm fit, function, or geometry without proving production readiness. Final materials, fixtures, process stability, inspection methods, tolerances, revision control, and documentation may still require validation.

What is the typical lead time for aerospace components?

It depends on the process, material, geometry, finishing, and inspection requirements. Straightforward prototypes can be completed in about 3–7 days in suitable cases, while titanium, Inconel, complex multi-axis machining, special finishing, detailed inspection, or material documentation can extend the schedule.

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Aerospace Manufacturing Services

CNC Machining

3-, 4-, and 5-axis machining for tight-tolerance brackets, housings, manifolds, mounts, interfaces, and complex curved components.

CNC Machining Services

3D Printing

Metal and polymer additive manufacturing for lightweight structures, lattice geometries, internal channels, complex prototypes, and low-volume parts.

3D Printing Services

Sheet Metal Fabrication

Laser cutting, bending, forming, and welding for lightweight brackets, panels, frames, shields, ducts, and equipment enclosures.

Sheet Metal Fabrication Services

Injection Molding

Repeatable molding for housings, covers, clips, brackets, and functional plastic components in engineering and high-performance thermoplastics.

Injection Molding Services

Metal Casting

Die, gravity, sand, and investment casting for metal housings and structural geometries where machining the complete shape becomes less practical at production volume.

Metal Casting Services

Vacuum Casting

Small-batch polyurethane parts for fit, assembly, appearance, and functional validation before committing to production tooling.

Vacuum Casting Services

Aerospace Product Development From Prototype to Production

Each stage addresses a different risk—from fit and interfaces to process stability, inspection, revision control, and repeat production.

Prototype

EVT

DVT

PVT

Production

Prototype Development

Validate geometry, interfaces, assembly, material direction, and basic function. Compare CNC machining, additive manufacturing, sheet metal, or molding before committing to a production route.

Concept Validation: Check part form, interfaces, and basic geometry.

Fit & Assembly Checks: Verify mating features, clearances, and component integration.

Build & Inspection: Compare candidate materials and manufacturing routes.

Design Iteration: Update CAD based on test and assembly feedback.

Engineering Validation Test

Verify critical dimensions, mating interfaces, tolerance stack-ups, thin walls, material behavior, and functional requirements using test-ready parts and targeted inspection.

Critical Dimension Verification: Inspect critical dimensions, interfaces, and datum relationships.

Functional Testing Support: Build parts for mechanical and functional evaluation.

Tolerance Review: Evaluate tolerance stack-up, thin walls, and critical mating features.

Manufacturing Feedback: Adjust geometry based on machining, molding, or additive manufacturing constraints.

Design Validation Test

Build production-representative parts where practical. Confirm form, fit, function, finishing effects, inspection methods, and remaining design changes before release.

Form, Fit & Function Validation: Confirm assembly compatibility and mechanical interfaces.

Material Behavior Validation: Evaluate material performance and the effects of finishing or post-processing.

Inspection Requirement Review: Define critical features and suitable measurement methods.

Final Design Release: Resolve remaining changes and prepare production-intent files.

Production Validation Test

Validate tooling, fixtures, manufacturing parameters, first-article requirements, inspection plans, and pilot production before scaling.

Tooling & Fixture Validation: Verify molds, fixtures, gauges, and production tooling.

Process Validation: Confirm manufacturing parameters and process stability.

FAI & Inspection Planning: Establish first-article and dimensional verification requirements.

Pilot Production: Run an initial batch before production scaling.

Production

Scale approved parts with controlled revisions, stable process parameters, inspection checkpoints, traceability, and batch consistency.

Batch Production: Run approved processes for low-volume and repeat production.

Revision Control: Maintain approved drawings, material specifications, critical requirements, and engineering changes.

Inspection & Documentation: Apply in-process and final inspection, with FAI, CMM or dimensional reports, material documentation, and traceability as required.

Delivery Planning: Coordinate production schedules, batch delivery, and replenishment requirements.

Custom Aerospace Components

Manufactured to your CAD and drawing requirements for material, GD&T, critical dimensions, surface finish, quantity, inspection, and documentation—from one-off prototypes to repeat production.

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Custom Aerospace Parts and Components We Manufacture

Part Category	Typical Aerospace Components
Structural Components	Brackets, mounting plates, frames, structural supports
Housings & Enclosures	Avionics housings, sensor housings, electronics enclosures, protective covers
UAV & Lightweight Components	Airframe brackets, motor mounts, camera and sensor housings, equipment mounts
Precision Mechanical Components	Shafts, bushings, couplings, precision interfaces, alignment and mounting features
Thermal & Fluid Components	Heat sinks, cooling plates, manifolds, ducts, fluid-routing components
Production & Test Tooling	Jigs, fixtures, inspection fixtures, assembly tooling, fit-check gauges

Aerospace Manufacturing Materials & Processes

Select materials by load, temperature, corrosion, weight, thermal or electrical requirements, and process; prototype materials may not reproduce final production behavior.

Material Category	Grades / Types	Manufacturing Processes	Aerospace Use & Engineering Considerations
Aluminum	6061, 7075	CNC Machining, Sheet Metal Fabrication	Common for lightweight brackets, housings, frames, and thermal components. 7075 provides higher strength but requires greater attention to corrosion protection and finishing requirements.
Titanium	Grade 5 / TC4, Ti-6Al-4V	CNC Machining, Metal 3D Printing	Selected where strength-to-weight ratio and corrosion resistance matter. Low thermal conductivity and high chemical reactivity increase cutting heat, tool wear, and machining time.
Stainless Steel	304, 316, 17-4PH by project	CNC Machining, Sheet Metal Fabrication	Used for corrosion-resistant housings, shafts, brackets, and precision mechanical parts. Heat-treatment requirements for precipitation-hardening grades should be planned with final dimensional control.
High-Temperature Alloys	Selected Inconel and nickel-based alloys	CNC Machining, Metal 3D Printing	Suitable for components exposed to elevated temperature or demanding mechanical conditions. Work hardening and low machinability can increase tooling requirements and cycle time.
High-Performance Thermoplastics	PEEK, PEI, PPS, reinforced grades	CNC Machining, Injection Molding, selected 3D Printing	Used where heat, chemical resistance, electrical properties, or weight matter. Processing temperature, moisture, shrinkage, and dimensional behavior depend strongly on the grade.
Engineering Plastics	PC, PA, POM, ABS and selected grades	CNC Machining, Injection Molding, 3D Printing	Useful for housings, covers, fixtures, prototypes, and functional components. Prototype polymers should not automatically be treated as equivalent to final aerospace production materials.
Composite & Reinforced Materials	FR-4, glass-fiber-reinforced polymers by project	CNC Machining, Injection Molding	Used for insulating, structural, and electronics-related parts. Fiber orientation, tool wear, edge quality, and dimensional stability require process-specific control.

Aerospace Post-Processing & Secondary Operations

Finishing can affect surface roughness, coating build, datums, threads, mating surfaces, and other critical interfaces.

Process	Applicable Materials	Typical Use	Engineering Consideration
Anodizing	Aluminum	Corrosion and wear protection for housings, brackets, and structural parts	Type II and Type III options; coating requirements should be considered on tight fits, threads, and mating interfaces.
Passivation	Stainless Steel	Corrosion protection for precision mechanical parts and housings	Suitable where corrosion resistance is required without a conventional deposited coating.
Sand / Bead Blasting	Metals & selected plastics	Surface preparation and uniform matte finish	Changes surface roughness and may affect sharp edges or precision surfaces; critical datums should be protected where required.
Powder Coating	Metals	Protective coating for enclosures, frames, and equipment parts	Coating build should be considered around holes, threads, fits, and assembly interfaces.
Painting	Metals & Plastics	Protective or specified cosmetic finishes	Surface preparation and masking affect adhesion, appearance, and dimensional interfaces.
Electroplating	Metals	Corrosion, wear, conductivity, or specified surface performance	Deposited thickness should be included when defining critical dimensions and mating surfaces.
PVD Coating	Metals	Thin hard coating for wear-sensitive surfaces	Coating type and final functional surface requirements should be specified before processing.
Laser Marking	Metals & Plastics	Serial numbers, identification, QR codes, and traceability	Marking position should avoid interfering with critical functional or inspection surfaces.
Heat Treatment	Metals	Hardness, strength, or material-condition requirements	Heat treatment can influence dimensional stability, so the manufacturing and final inspection sequence should be planned accordingly.
Insert Installation	Metals & Plastics	Threaded and assembly interfaces	Insert position, installation method, and final interface requirements should be included in the drawing or RFQ.

Aerospace Manufacturing Case Studies

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