AS9100 REV D CERTIFIED · ITAR REGISTERED · NADCAP ACCREDITED EST. 2009

ENGINEERED BEYOND LIMITS.

Vertically integrated aerospace manufacturing — AS9100 Rev D, FAA Part 145, NADCAP, ITAR. We design, machine, composite-fabricate, assemble, and qualification-test flight-critical hardware for commercial aviation, defense, and space programs. One engineering team. One quality system. Total accountability from billet to flight-cleared shipment.

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FAC: CAPE CANAVERAL, FL
FLOOR: 340,000 SQ/FT
PERSONNEL: 480 ENG.
00:00:00 UTC
TOLERANCE: ±0.0005" (12.7 µm)
ASTROVA SYSTEMS ✦ AS9100 REV D CERTIFIED ✦ PRECISION CNC MACHINING ✦ ADVANCED COMPOSITES ✦ AVIONICS INTEGRATION ✦ FAA PART 145 APPROVED ✦ NADCAP ACCREDITED ✦ ITAR REGISTERED ✦ ISO CLASS 7 CLEANROOM ✦ NDT LEVEL III INSPECTION ✦ FIRST ARTICLE INSPECTION ✦ ASTROVA SYSTEMS ✦ AS9100 REV D CERTIFIED ✦ PRECISION CNC MACHINING ✦ ADVANCED COMPOSITES ✦ AVIONICS INTEGRATION ✦ FAA PART 145 APPROVED ✦ NADCAP ACCREDITED ✦ ITAR REGISTERED ✦ ISO CLASS 7 CLEANROOM ✦ NDT LEVEL III INSPECTION ✦ FIRST ARTICLE INSPECTION ✦
0 K+ VERIFIED FLIGHT HOURS
0 .7% FAI FIRST-PASS RATE
0 + PRODUCTION PROGRAMS
0 FAA DARS ON STAFF
01

WE DESIGN
TO FLIGHT

CATIA V5/V6, ANSYS FEA/CFD, MBSE on IBM DOORS NG. GD&T drawing sets to ASME Y14.5-2018, FEA margin summaries to MMPDS-12, FMEA/FTA per SAE ARP4761, and DVPs cross-referenced from MIL-HDBK-5 through ECSS-E-ST-32. Every margin reviewed at DRB before manufacturing release. Full PLM audit trail on every revision.

Earth from orbit
02

WE BUILD
TO TOLERANCE

±0.013mm (±0.0005") on Ti-6Al-4V, Inconel 718, and 7075-T7351 — Zeiss CONTURA G2 CMM at 0.7 µm, never by the operator who made the cut. 18,000 sq/ft composite cell: Cincinnati Viper 6000 AFP, 6.0m × 3.2m autoclave at 400°F/350 psig with 72-channel thermocouple cure monitoring. No CTF dimension ships without a recorded, signed inspection result.

International Space Station
03

WE QUALIFY
TO STANDARD

3,000 lbf shaker (20–2,000 Hz, 3,000g SRS), Tenney thermal (−73°C to +175°C), Thermotron thermal vacuum (10⁻⁶ torr), and He leak detection to 1×10⁻⁸ scc/sec — all in-house. Standards: MIL-STD-810H, DO-160G, NASA-HDBK-7005, GEVS-7000A. Test what you fly. No approximations, no exceptions.

Pillars of Creation nebula

PROGRAM
HIGHLIGHTS

Flight-qualified hardware across commercial, defense & space domains. Drag to explore →

PROGRAM · COMMERCIAL AVIATION

FUSELAGE FRAME ASSEMBLY

7075-T7351 aluminum fuselage station frames produced to FAR Part 25 standards — 43 machining operations, 14 CMM checkpoints, dye-penetrant on all fillets. Material removal ratio: 82%. Delivery cycle: 18 working days.

● IN PRODUCTION
PROGRAM · SATELLITE / SPACE

SATELLITE STRUCTURAL CHASSIS

1.2m × 0.8m CFRP honeycomb sandwich panel for GEO communications bus — Hexcel HexPly M21 layup, autoclave-cured, qualified to ±0.15mm flatness across full panel. Survives 9.5g axial launch load and 15-year GEO thermal cycling.

◆ SPACE QUALIFIED
PROGRAM · DEFENSE / UAV

MALE UAV AIRFRAME STRUCTURE

CFRP monocoque airframe for DARPA-funded long-endurance unmanned platform — 22% weight reduction via topology optimization, 6g ultimate load factor, 28-hour endurance profile. Full MIL-DTL-31000 data package included.

◇ EXPORT CONTROLLED
PROGRAM · COMMERCIAL AVIATION

TURBOFAN NACELLE COMPONENTS

IFS bifurcation duct in hybrid CFRP/glass fiber laminate — autoclave-cured to ±2°C uniformity via 48 embedded thermocouples, bonded to titanium edges per Boeing D2-70061. Acoustic liner: 3,240 inspected NOMEX cells per panel. Rate: 12 assemblies/month.

● RATE PRODUCTION
PROGRAM · AVIONICS

AVIONICS LRU INTEGRATION

IPC-A-610 Class 3 avionics rack and harness assembly — MIL-DTL-38999 connectors, AS22759 wire spec, ARINC 429 / MIL-STD-1553B databus integration. 100% functional test before shipment. FOD sweep log every shift.

◇ MULTI-PROGRAM

AEROSPACE IN
ACTION

Flight-qualified hardware delivered to orbital, defense, and commercial programs across 5 continents.

Rocket launch — orbital manufacturing programs LAUNCH SYSTEMS · FAR PART 25 · ORBITAL MANUFACTURING
Avionics circuit board — IPC-A-610 Class 3 integration AVIONICS · IPC-A-610 CLASS 3
Deep space — GEO satellite programs SPACE QUALIFICATION · GEO SATELLITE BUS
Aerospace engineering lab — qualification testing ENGINEERING LAB · NDT · FRACAS
Space exploration — deep space mission hardware DEEP-SPACE PROGRAMS · MIL-STD-810H · GEVS-7000A

PROGRAM
GALLERY

Flight-qualified hardware delivered across commercial, defense & space domains.

Rocket launch — launch systems engineering
PROGRAM 01 · LAUNCH SYSTEMS
LAUNCH VEHICLE STRUCTURES
Avionics circuit board — IPC-A-610 Class 3
PROGRAM 02 · AVIONICS INTEGRATION
IPC-A-610 CLASS 3 ASSEMBLIES
Deep space — satellite structural programs
PROGRAM 03 · SPACE QUALIFICATION
GEO SATELLITE STRUCTURAL CHASSIS
Engineering facility — qualification testing
PROGRAM 04 · ENVIRONMENTAL TEST
MIL-STD-810H QUALIFICATION LAB
Space exploration — deep space hardware
PROGRAM 05 · DEEP SPACE
DEEP SPACE MISSION HARDWARE — GEVS-7000A

BUILT TO
FLIGHT STANDARD

Zero safety-of-flight escapes. 500,000+ verified flight hours. 98.7% FAI first-pass rate across 1,400+ programs. Zero major NCs in three consecutive AS9100 audits. Documented, auditable records — available under NDA.

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PROGRAM LIFECYCLE — CONCEPT TO FLIGHT QUALIFICATION
DESIGN RELEASE FIRST ARTICLE INSPECTION FLIGHT QUALIFICATION

CORE
CAPABILITIES

Precision CNC machining — avionics and circuit systems

5-AXIS CNC MACHINING

DMG Mori & Mazak 5-axis centers hold ±0.013mm on Ti-6Al-4V, Inconel 718, and 7075-T7351. Zeiss CONTURA G2 CMM at 0.7 µm. Cell at 68°F ±0.5°F. Cpk >1.67 required on all CTF dimensions before production release.

Advanced composite aerospace structures — launch vehicle

ADVANCED COMPOSITES

AFP (Cincinnati Viper 6000), hand layup, RTM, autoclave at 400°F/350 psig. Qualified: Hexcel M21, IM7/977-3, T800/MTM45, NOMEX honeycomb. NADCAP AC7118/4 Merit Status. 72-channel cure monitoring per cycle.

AS9100 quality assurance — space program precision

AS9100 QMS & INSPECTION

Zero major NCs in three consecutive AS9100 Rev D audits. NCR rate: 0.31%. 100% AS9102 FAI per new part number. FRACAS to 5-Why. Zeiss CMM (0.7 µm) · FARO laser tracker (0.016mm) · PAUT · computed radiography.

Environmental qualification testing — deep space programs

ENVIRONMENTAL TEST LAB

3,000 lbf shaker · Tenney −73°C to +175°C · Thermotron thermal vacuum 10⁻⁶ torr · He leak to 1×10⁻⁸ scc/sec. PAUT, CR, PT/MT/ET — ASNT Level II/III. Standards: MIL-STD-810H · DO-160G · GEVS-7000A.