Adaptive Manufacturing for Aerospace and Defense

Background

PGC has a strong and longstanding relationship with a contractor specializing in solving challenging problems in space, aeronautics, defense, and cyberspace. This customer is well-known for creating and delivering advanced systems, products, and services to meet customers' evolving needs worldwide. Due to their partnership with PGC, this customer  had confidence in our application engineers' expertise to provide a solution accurately and efficiently.

Challenge

With a fast-approaching deadline for one of their part programs, this contractor asked PGC application engineers to help create a munitions spacer to be used in one of their assemblies. These spacers are usually a molded part, which can increase lead-time and price exponentially. These spacers would be used in design verification testing and the assembly would likely see multiple changes throughout this process, which made price even more of a significant factor. Due to the extensive documentation and control requirements in the ASD industry, being conscious of production time would be paramount, as proposed changes can take a long time to be approved. With all these different factors in mind, PGC application engineers had to think of a creative solution that would minimize cost and prepare for the likelihood of future design changes.

Solution

The original curved part, which was not well-suited for molding manufacturability, was redesigned to be manufactured flat and then bent into a curved shape during installation. This new design, coupled with the use of pressure-sensitive adhesive (PSA), ensured that the part maintained its curvature for customer use while avoiding investing in a complex and expensive die, which could delay delivery and increase price. PGC's solution to the challenge was innovative and effective by proposing a different arrangement of the parts.  PGC was able to significantly reduce tooling, manufacturing lead time, and program costs. 

Results

PGC's effective communication and implementation of necessary changes expedited the order process, allowing the company to meet the customer's requested delivery date. The customer was delighted to receive their order on time and at a significantly reduced cost, a result of PGC's efforts to expedite their order and maintain part quality.