At Reata Engineering, tackling complex challenges is our specialty. We embrace every project as an opportunity to find innovative solutions and deliver the results our customers need. But we’re not just focused on meeting requirements—we’re committed to building strong, lasting partnerships with our customers, working closely with them to ensure success at every stage of the process.
Recently, an aerospace customer requested a hydraulic cylinder component that included very specific testing requirements. It needed to withstand assembled pressures exceeding 10,000 PSI. In reviewing the project, our team knew we would handle the precision machining side with ease, but we faced two key challenges:
- Reverse engineering the testing procedure due to a lack of documentation, and
- Developing a robust testing process to verify its performance.
Our Rigorous Approach to Aerospace Machining
As always, our talented engineers and machinists were up to the task. Our process to develop this part was as follows:
Step 1: Understanding customer requirements
Before we move forward with production, it’s vital that our team understands exactly what our customer needs and expects from us. Our new part meetings set the tone for our partnership and ensure everyone involved in the project is aligned.
Step 2: Reverse engineering the process
Our customer needed comprehensive documentation for the testing procedure necessary to develop this product. Their previous supplier had kept this information proprietary, a common practice to deter customers from switching vendors. At Reata we take a different approach. Our team reverse-engineered this testing procedure and created detailed documentation for our customer.
We granted full ownership of this documentation to our customer, empowering them to make any necessary changes in the future. We’ve found that rather than holding documentation hostage, we have greater success building strong, long-term partnerships founded in openness and trust.
Step 3: Building a virtual twin
With the testing process established, our next step was to create a virtual twin of the part using Solidworks. This enabled the Reata team to:
- Understand how components would work together
- Analyze forces and stress points
- Conduct finite element analysis to identify potential issues
In this particular project, we engaged in iterative prototyping for necessary fixtures and tooling. When challenges arose, we returned to the virtual model, conducting further analysis to pinpoint stress points and develop solutions accordingly.
Step 4: Machining
While this was a relatively complex aerospace component that required tight tolerances, its specifications were well within our capabilities. Our experienced team handled all ID grinding and heat-treating services with precision, ensuring each component met the exacting standards required for aerospace applications.
Step 5: Developing in-house testing equipment
This unique component required hydrostatic proof load testing, which was outside our bandwidth at the beginning of this project. Rather than outsourcing the testing procedure necessary to complete this project, Reata brought the entire process in-house. Our expert engineering team designed and manufactured all the required tooling and testing equipment, ultimately adding a new capability we can offer customers in the future.
Partner with Reata for Top-Notch Precision Machining
This project pushed our team to think outside the box, ultimately showcasing our expertise in manufacturing and testing high-precision parts. This experience not only demonstrates our expertise in aerospace machining but also highlights our ability to handle complex projects across various industries.
Here’s how we stand out:
Open communication
Throughout the project, we maintained an open line of communication with this customer. We held regular meetings to ensure alignment on goals and progress and discuss potential challenges.
Transparency in our processes
As demonstrated by our openness to sharing all documentation, our team gives our customers ownership of the process, building trusted partnerships.
Engineering support
Our engineering team’s ability to design tooling, develop testing processes, and solve complex problems as needed showcases our expertise and commitment. We are a true engineering partner.
More than a Solutions Provider
At Reata, we don’t just deliver solutions; we build lasting partnerships. If you’re looking for a contract manufacturer that combines technical excellence with a customer-focused approach, we invite you to request a quote and experience the Reata difference for yourself.