Machining:

Whether it requires manual milling and turning or high-speed vertical or horizontal 5-axis simultaneous CNC machining, Malone’s has the equipment and experience to be competitive in today’s low to high quantity aircraft spares market.

Sheet Metal:

Manufacturing aircraft sheet metal spares requires the ability to combine old and new manufacturing methods and technologies.  For example, older aircraft were designed and manufactured using full-scale, partially un-dimensioned mylars.  Many part contours are manufactured to loft line drawings. Malone’s utilizes a high accuracy, magnified digital process to convert full-scale drawings into a digital format that is used to reproduce the component as a 3D model.  This capability allows our engineering department to pre-assemble and mate components in a 3D environment, transfer all required fastener holes, then extract all the components with the additional fastener holes in the proper locations.  This virtual assembly process eliminates the need for elaborate and costly assembly fixtures and drill jigs.  Malone’s utilizes this proven process to manufacture everything from a simple sheet metal bracket to a complex, formed, multi-component assembly.

 Assembly:

Malone’s is proficient in performing many types of assembly processes. Some of these processes include:  riveting, welding, brazing, shrink fitting, bonding and hardware installation.

 Other manufacturing processes utilized by Malone’s:

High speed stamping          Plastic injection molding   
Plastic vacuum forming     Post forming laminates
Fiberglass lay-ups              Wire harness assemblies
Resin potting                        Dynamic water jet