Duncan Aviation has expanded and reorganised its parts manufacturing and fabrication areas, creating a new division called Duncan Manufacturing Solutions.

Duncan Manufacturing Solutions (DMS) is currently serving in-house needs for Duncan projects and customers as well as requests from aviation system and aircraft manufacturers, but the expectation is that the area will grow in the future to provide services to companies in other industries that need high-quality parts to meet scheduling needs.

More than $4 million has been invested in the DMS facility, which was built adjacent to its turbine engine overhaul shop in Lincoln, Nebraska, and has 21,000 sq ft devoted to machining, metal work and composite capabilities.

“The expansion is exciting, and our ability to create complex geometries with tight tolerances is impressive,” says Scott Stenka, Duncan Manufacturing Solutions manager, “but it really is an extension of work we have performed for nearly 38 years through our FAA parts manufacturing approval authorisation.”

It has added more sophisticated equipment to supplement its previous capabilities and machinery to allow for various CNC milling, waterjet cutting, metal press, engraving and heat-treating capabilities.

With the addition of the HAAS VF5, DMS will effectively double its milling output. Its HAAS UMC750 five-axis allows for the machining of complex parts with great accuracy and minimal setups. Duncan also added an Epilog Fusion Pro 48 Dual Laser Engraver. It doesn't require a perfectly flat surface to remove paint or etch. It is configured with both a CO2 and a fibre laser.

DMS brought heat treating capabilities in-house with the addition of two Delta H Heat Treat Ovens. The ovens are capable of heat treating aluminium, stainless steel, tool steel and titanium. An Omax 60120 Waterjet replaces the existing water jet cutting machine expanding the ability to fabricate sheet metal parts.

The positive airflow composite shop is equipped to handle prepreg composite repairs and manufacturing. It features a 1,150 sq ft clean room and a paint booth with a mixing room. Advanced repairs and manufacturing capabilities are accomplished with the purchase of the ASC AutoClave, this machine is used to cure carbon fibre, Kevlar and fibreglass materials to repair or construct new parts.

A new DMS Hexagon Absolute seven-axis arm was installed to inspect all of the items produced by DMS. The seven-axis arm is a multi-functional measuring tool for precision, first-article inspections and reverse engineering when paired with the RS6 laser scanner.