Creating an Aerospace Future

Causeway Aero Limited has been formed by five SC21 accredited Northern Ireland aerospace companies who have come together to offer combined capabilities to the aerospace sector.

This enables larger and more complex design and manufacture work packages to be undertaken.

The participating companies are well established in the aerospace sector with extensive approvals and are supplying amongst others, Airbus, BAE, Bombardier, GKN and Spirit.

The participating companies are as noted below who continue to operate independently as privately owned separate companies as well as participating in Causeway Aero:

Causeway has been formed in response to a demand from the industry for suppliers who are capable offering a broader range of skills, including design, to enable more complex work packages to be undertaken.

The initiative is aligned with the Aerospace Growth Partnership strategy to encourage industry “Tier 3” suppliers to move upwards in the supply chain where opportunities and needs have been identified.

The structure is unique and has the full support of ADS and Invest Northern Ireland who have assisted with funding through their Collaborative Network Programme.

Causeway Offering : Products & Services

• Aerospace structures design• Stress engineering• Design for manufacture• Plastics injection moulding• Machining services – 3 and 5 axis • Sheet laser punching• Metal forming and welding• Treatments and painting• Inspection• Tools and fixtures manufacture• Access to composites manufacturing• Assembly including sub-structures• Kitting

Causeway Offering : Contracts

• Single point of contact for project management

• Single entity for contracting

Aerospace Structures Design

Aerospace design services are provided by BASE Ltd

• Formed in 2000 in Belfast and employ +30 design and stress engineers

• AS/EN9100 / ISO 9001 “Rev C”

• SC21 Bronze awarded at Farnborough 2016

• Supply more than 30 customers in the EU and the US and have completed more than 100 projects, delivering over 500,000 hours of engineering

• Advanced Toolset : Catia V5, Nastran, Patran, Dytran, NASGRO, others

• Designs range from concept layouts to detail design, composite and metallic, structures design, FD&T, PT&A and GD&T

Aircraft Structure

Nacelles Composites Systems Interiors Airframe

Stress Analysis

Stress analysis services are provided by BASE Ltd:

• Initial concept & trade studies• Metallic and composite materials• Static Analysis• Fatigue and Damage Tolerance Analysis• FEM – Nastran, Patran, Marc, Dytran• Linear & non-linear• Optimisation• Test Programme support and analysis• Primary and secondary structures and interiors

• Specialist services also provided on vibration, acoustic fatigue, GD&T, thermal, loads and CFD

Previous Design Experience

• Fuselage – Bombardier CRJ/Global/Lear/Dash 8, Airbus A340/A400M, Nimrod, TriStar

• Wing, Tail and Flights - C-Series wing, flaps, spoilers, A320/A400M spars & FTE, A350 Spars, A380 L/E & Flap track fairings, CRJ700/1000, Global elevator & rudder

• Nacelles - Rolls Royce Tay 611C, Trent, RB211 E4B, V2500, PW1400G, Allison AE3007r

• Interiors - completions A340, B747, B777, A320, B737, crew rest A380, galleys – G1, G2, G5 – Airbus single aisle, seating and monuments B/E and Contour

Plastics, Composites and Assembly Services

Advanced plastics manufacturing capability provided by DENROY Plastics Ltd.

Established in 1972 and employs 150 people, core services include:

• Materials selection experience, specialising in metal and composite replacement

• Leading processing capability on high grade aerospace polymers including PEEK

• Rapid prototyping and lower cost tooling using 3D printing and liquid pour technology

• Design for manufacture including tooling production using CATIA, Pro/ENGINEER Wildfire, Moldflow Advisors

• Plastics injection and compression moulding and access to composites capabilities as required, 40 injection machines with full tool manufacture capabilities

Plastics, Composites and Assembly Services

Current programmes include:

• Civil – Airbus A320/A350/A380, Bombardier C Series, Global and Learjet

• Defence – Typhoon with over 180 components, A400M, Hawk

Current products and services include:

• Wing fairings, internal wing brackets including PEEK based products, interior fixings and components

• Product machining, painting, bonding, ultrasonic welding, assembly and kitting services

• High grade plastics finishing and advanced printing capability for logos, etc on aircraft interiors

Plastics, Composites and Assembly Services

Denroy Approvals include:

• AS/EN9100 / ISO 9001 “Rev C” approval from BSI• UL Approval for moulding QMMY2• BS8555:2003 Environmental (part 4)

• Airbus (151906)• BAE SYSTEMS (BAE/AG/10258/MAA)• Bombardier Aerospace (S/011363 SB/VC/189)• Thales Air Defence (VC01/0338-03)• Spirit Aerosystems (0470)• GKN Aerospace (GKNAF00131)• CTRM (CTRMAC/3-B/007)• SC21 Bronze Award (Nov 2012)• SC21 Silver Award (July 2014)

Machining and Assembly Services

Machining services are provided by Moyola Precision Engineering.

Formed in 1972 in Castledawson, Northern Ireland and employing 120 people, core services include:

• 5 axis CNC milling – capacity up to 3.8m x 2.0m• Titanium machining• Milling and turning capabilities including full 5-axis contouring• Kits and sub-assemblies• Tooling, jigs and fixtures manufacture• CADCAM – Catia V5• Quality - CMM’s with full CNC control, offline programming capability

using PCDMIS CAD++, Direct Cad Interface (DCI) to Catia (to maintain total integrity of Catia model)

Machining and Assembly Services

Moyola manufacture aerospace components for both the civil and defence sectors, current products include:

• Leading Edge Wing Rib• Fuselage• Nacelle• Bulkhead aluminium components• Hard metal components & sub-assemblies in stainless steel &

titanium• Assembly - installation of bushings, bearings, sealants, elastic

protective coating, etc• Jigs, fixtures, tooling and assemblies for aerospace commercial and

defence including one off bespoke complex components

Machining and Assembly Services

Approvals include:

• BS EN ISO 9001-2000 / AS EN 9100 Rev C• Investors in People & Excellence Through People• Bombardier machining, assembly and tooling approvals• Airbus machining approval• BAE Systems approval• GE Aviation machining and assembly approval• GKN Aerospace approval• Spirit Aerosystems approval• Langford Lodge machining approval• Thales machining and tooling approval

A full range of machining services are also provided by sistercompany to AMF, Dontaur Precision Engineers, also a participant in Causeway.

Sheet laser punching and metal forming Services

Sheet laser punching and metal forming services capability is provided by Hutchinson Aerotech

Based in Antrim, Northern Ireland with over 40 years experience in engineering, core services include:

• Laser cutting- capacity up to 3m x 1.5m and 6mm• Forming – capacity up to 3.2m and pressure of 130T• Deburring (NADCAP approved) - part size up to 3.05m x1m and

thickness of 50mm• Engineering - Catia V5, Solidworks• Inspection testing including Electro-Chemical etch, DOT Peen and

part read verification systems

Sheet laser punching and metal forming Services

Current Components:

Sheet laser punching and metal forming Services

Current Approvals

• AS9100 Aerospace Quality Standard

• NADCAP

• Bombardier Aerospace approval

• SC21 – Supply Chain Programme

• Own SQA of our sub suppliers

Treatments and painting services

Treatment and painting services capability is provided by Aerospace Metal Finishers (AMF), precision engineering services also provided by sister company Dontaur Precision Engineers.

Based in Ballymena, Northern Ireland and established in 2002, core services include:

• Chemical Processes – anodising, conversion coating, passivation of stainless steels, pre PFD etch

• Laboratory - taber abrasive testing, salt spray testing, coating thickness testing, chemical analysis

• Blasting – vapour, dry, glass bead, plastic bead• Painting – PTFE, dry film lubricant, heat resistant• NDT -magnetic flaw detection, fluorescent penetrant inspection,

hardness Testing, electrical conductivity• Heat Treatments - de-embrittlement, stress relief

Treatments and painting services

Current Approvals

• BSI/AS/EN9100 REV B, BS EN ISO 9001:2000• BSI/BS EN ISO 14001:2004. • NADCAP Management Council - SAE Aerospace Standard

AS7003 in Chemical Processing and NDT • Vendor Inspection Program Supplier with Bombardier

Aerospace and hold Bombardier Aerospace full approvals in Chemical Processing and NDT

Causeway Aero Offering

• Causeway offers the aerospace industry a new option in terms of design and manufacture with the advantage that supply of the complete package can be outsourced and consolidated

• This offers access to a range of services including design and manufacture with a single point of contact and a single entity for contracting

• The participating companies are well established with a combined turnover of over $70m and around 500 employees

• Extensive capabilities across design, stress, machining, forming, plastics, painting and treatmentsand assembly, numerous approvals across the companies including SC21 and AS9100

• Causeway Aero Limited has been formed and several design and build projects are already underway

• The company seeks further projects and is ready to meet the needs of the industry

Causeway Aero Contact Details

Contact: Mr Paul ShieldsEmail: paul.shields@causeway.aeroTel: 0044 7739 490680

0044 2890 426271

Website: www.causeway.aero