Manufacturing

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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.

 
 

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
  • Manufacture of Aircraft Power Systems, Structures and Flight Control Surfaces.
  • 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