Manufacturing

Search form

Northstar Aerospace is committed to manufacturing and delivering products that meet customer requirements. We build quality and reliability into our products and processes by leveraging best practices and strategic planning. We expect our employees to take ownership and promote a proactive work environment based on team member involvement and problem solving. Northstar Aerospace is dedicated to continuous improvement and will work to improve the effectiveness of our quality management system and the quality of products offered.
All Northstar sites are certified and registered to ISO: 9001-2008, SAE AS9100:2009, Rev. C. Each site has appropriate NADCAP certifications applicable to their product lines.

 
 

Chicago Facility

Bedford Park, Illinois, USA 60638

Leading independent manufacturer of helicopter transmission components in the United States

ISO 9001:2008

AS9100 Rev C

NADCAP certified in Chemical Processing, Heat Treating and NonDestructive Testing

Boeing D1-4426 approved for multiple special processes

Offers turn-key services for drive train requirements including design and manufacturing engineering; manufacture of quality gearing; program management; heat treatment; plating; NDT capabilities including Magnaflux, Zyglo and Nital Etch; precision assembly; dynamic testing

Original and primary manufacturer of transmission gearing, kits and drive components for CH-47 Chinook family of rotorcraft, as well as, MRO services on the forward, aft and combiner transmissions

Original manufacturer of AH-64 Apache main transmission. Also serves as depot repair station for Apache transmission overhaul.

Manufactures, assembles, tests the Airframe Mounted Accessory Drive (AMAD) unit for the F-22 Raptor fighter jet and provides repair and overhaul services

 
 

Milton Facility

Milton, Ontario, Canada L9T 3H5
At Northstar Aerospace (Milton) our diverse operational and technical capabilities provide a one-stop solution for our Aerospace and Defense customers. Through decades of research and development tightly linked to a lean, continuous improvement culture, diverse manufacturing capabilities and a highly skilled workforce, our state-of-the-art facility is geared to respond to the needs of our current and future customers.

  • Product Lines – Northstar Aerospace (Milton) manufactures finished products for our customers in the following product families:
    • Face Gears
    • Bevel Gears
    • Spur Gears
    • Helical Gears
    • Shafts (Dynamically balanced)
    • Rotor Heads
    • Fully Assembled and Tested Gearboxes and Power Take-Off (PTO) Units
  • Materials – Northstar Aerospace (Milton) manufacturing and processing experience covers a wide range of materials:
    • Aerospace Steels
      • AerMet 100
      • AMS 4130
      • AMS 4140
      • AMS 6265
      • AMS 6419
      • H-53 Pyroware
    • Aerospace Corrosion Resistant Steels
      • AMS 5629
      • BS99
      • S144
    • Aluminum Alloys
      • AMS 4141
    • Magnesium
      • AMS 4429
    • Titanium
      • 10-2-3
      • 6-4
  • Engineering – Northstar Aerospace (Milton) features an experienced and highly skilled engineering staff:
    • Unigraphics and SolidEdge – For Gear and Tool Design
    • Unigraphics and MasterCAM – For Manufacturing Engineering and NC Programming
  • Manufacturing and Inspection – Northstar Aerospace (Milton) is outfitted with state of the art manufacturing and inspection equipment:
    • Face Gear Shaping Machine
    • 2 CNC Face Gear Grinding Machines
    • 5 CNC Gear Grinders
    • Assembly and No-Load Gearbox Test Benches
    • 4 Zeiss Coordinate Measuring Machines (CMM’s)
  • Special Processes, Heat Treatment and Non-Destructive Testing – Northstar Aerospace (Milton) has developed and maintains highly specialized processing capabilities, including current NADCAP, industry and customer certifications:
    • Heat Treatment
      • Carburize
      • Harden
      • Freeze
      • Stress Relief
    • NDT
      • Magnetic Particle Inspection
      • Nital Etch Inspection
      • Flourescent Penetrant Inspection
    • Plating
      • Copper
    • Paint and Dry Film
  • Certifications – Northstar Aerospace (Milton) maintains a wide range of industry and customer certifications. Our NDT Level III personnel and other specialists aggregate many years of experience in inspection, testing and metallurgical evaluation:
    • ISO 9001:2008 and AS9100 Rev C
    • NADCAP
    • Boeing D1-4426
      • BSS7040, Magnetic Particle Inspection
      • D210-12023-1, Carburizing of Steel
      • D210-12049-1, Cleaning Transmission, Rotor Head Passages and Orifice
      • HP1-1, Heat Treatment (Steel)
      • HP1-9, HT Steel, Hydrogen Embrittlement Relief
      • HP2-2, Carburizing (Steel)
      • HP4-15, Supplementary Chromate Treatment
      • HP4-113, Brush Plating
      • HP6-5, Magnetic Particle Inspection
      • HP18-12, Low Stress Grinding (High Strength Steel)
      • HP30-4, Etching for Detection of Grinding Burns
      • MIL-C-14550, Copper Plating
      • MS8.17, Black Oxide Treatment of Steel
      • NAS 410, NDI Personnel Certification Level III (Magnetic)
    • GE
      • GT193, Category 1 Certification
      • GT193, Magnetic Particle Inspection
 
 

Phoenix (D-Velco Aviation Services)

Phoenix, Arizona USA 85034-2500

  • D-Velco Aviation Services offers military and commercial (FAA and EASA) engine component and structural repair and overhaul services.  These include containment rings, hot section components, airflow, and a number of airframe control surfaces and components. 
  • Full paint, sheet metal, mechanical, composite and inspection departments
  • Rotable Exchanges
  • Machining, Welding, Flame Spray, Painting and Plating
  • DER Component Repair and Owner-produced Parts Development
  • Material Fabrication
  • Phoenix Pickup and Delivery
  • Located near Phoenix Sky Harbor International Airport
  • This Repair Station Location is listed under Heligear Acquisition at FAA.gov RepairStation listings
  • Certifications
  • Aircraft Types Served:

BOEING

AIRBUS

CRJ

B717

A300

100

B727

A310

200

B737

A318

700

B747

A319

900

B757

A320

 

B767

 

 

DC9

 

 

MD80

 

 

Series MD90

 

 

Series DC10

 

 

MD11

 

 

 
 

Phoenix Facility

Phoenix, Arizona USA 85034-2812

  • Scope: Manufacture of aircraft power systems, structures and flight control surfaces
  • Highly respected contract manufacturer for North American aerospace industry
  • Manufactures complex, fabricated and machined components for leading engine and aircraft builders and U.S. military. Fixed and rotary wing aircraft in commercial and military applications.
  • Fabricated engine products: Capabilities include hydro forming; draw, roll and brake forming; laser fitting and welding; vacuum bonding; titanium inert chamber welding, seam, spot and overlap spot; CNC TIG welding; TIG welding
  • ISO 9001:2008 and AS9100 Rev C
  • NADCAP certified for Weld (Tig, Seam, Spot), Chemical Processing and NDT (MT, PT, RT)
  • Boeing D1-4426 approved for multiple special processes
  • Machined components: 24 machining centers from 3-4-5 axis CNC machining centers up to 5 foot cube; 13 CNC turning centers with 58 inch diameter capacity; multi-spindle FMS application and eight single spindle palletized cells; tooling and support shop
  • Composite manufacture: Wet lay-up and pre-preg applications; 10’ x 30’ autoclave; curing ovens; hot bond table; controlled environment lay-up room
  • Organic/inorganic coatings: Painting and wipe coats; anodizing for magnesium; chemical conversion coating of aluminum
 
 

Windsor Facility

Tecumseh, Ontario, Canada N8N 2L9

 

  • Leading manufacturer of precision gears (spiral, helical, spur), curvics, shafts, splines from prototype to high volume production
    • ISO 9001:2008
    • AS9100 Rev C
    • NADCAP certified for Chemical Processing
    • Boeing D1-4426 approved
    • DoT approved
    • Machining capabilities include: CNC turning; CNC milling; CNC grinding; gear generating/grinding; curvic grinding; hobbing; shaping and broaching from ¼ inch to 24 inch in diameter up to 40 inch lengths
    • Inspection competencies include: Zeiss® CMM; Mitutoyo® CMM; M&M® gear analyzer; Hommel® optical measuring equipment
    • Sole provider of IGB (internal) gear package, SAGB (Step Aside) gear package and angled drive shaft for Rolls-Royce Trent 1000 engines used to power the Boeing 787 Dreamliner aircraft

Customer/Quality Specifications

  • AgustaWestland QRS01
  • AMCOM QE-STD-1
  • Boeing D1-9000
  • General Electric S1000
  • Hamilton Sundstrand ASQR-01
  • Rolls-Royce RR 9000:SABRe
  • Sikorsky SQAR-100
  • Columbia Helicopters 06-RDE-0116-2

 

Supplier Quality Requirement Documents