Kaman Tooling Ltd

(Artists Impression)

ONE KAMAN - Truly Global

Civilian & Military Aerospace

Fixed Wing - Rotary

Space Applications

Fuzing & Precision Products

Kaman Aerospace Group

Aerosystems

Specialty Bearings & Engineered Products

Air Vehicles & MRO

Metallic's & Assembly

Composite Structures

Annual Sales $1.6 BN

4,800 Employees

Headquarters: Bloomfield, Connecticut

Listed on NYSE: KAMN Company Restricted

Engineered Products

Engineering Services

Greg Steiner President

Jim Larwood

President

Jerry Ricketts Division President

Precision Products

Rob Paterson Division President

Speciality Bearings

Bob Manaskie General Manager

Cliff Ward VP/General Manager

Bob Kanaskie Division President

Al Lariviere Division President

Kaman Aerospace Worldwide Locations

Helicopters

Precision Products

1. Middletown, CT

2. Orlando, FL

3. Tucson, AZ

4. Bloomfield, CT

5. Dachsbach, DE

13. Jacksonville, FL

14. Chihuahua, Mexico

7. Bloomfield, CT

8. Wichita, KS

9. Lancashire, UK

10. Bennington, VT

11. Goa, India

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Aerosystems Engineered Products

Fuzing & Precision Products

Specialty Bearings & Engineered Products

Air Vehicles & MRO

Metallic’s & Assembly

Composite Structures

Engineering Services

6. Bloomfield, CT

12. Everett, WA

India (JV)

Lo-cost

Slovakia

Lo-cost

Chihuahua

Lo-cost

Lo-Cost (options)

India: Composites

Chihuahua: Metallic’s

Slovakia: Tooling Fabrications

Kaman Aerospace Group Aircraft Product Portfolio – Fixed Wing

Doors (inc MLG & NLG)

Shielded Consoles

Cowlings, Nacelles,

Thrust Reverser Doors

Engine Handling

Wing Structures

Fairings & Panels

Floor Structures

Control Surfaces

Stairs

Radomes

Fuselage Structures

Winglets

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Transportation: Handling / Lifting

Moveable Systems

Containerisation

Maintenance

Doors

Engine Inlet

Screens

Tunnel Covers

Rotor Blades

Ramps

Sponsons

Floors

Pylons

Cockpits

Cabin Interiors

Shaft Couplings

Transition/Boom

Fuselage Structures

Kaman Aerospace Group Aircraft Product Portfolio – Rotorcraft

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KAMAN Tooling is a centre of excellence for Aerospace Tool Design - Manufacture - Installation

Consisting of a large highly skilled multi-disciplined team,

supporting major primes and tier 1 customers on some of the most

advanced aircraft projects in development and production.

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Tooling Design & Manufacture

Tooling & Composite Specialists:

Project Management

Turnkey solutions, concurrent & reverse engineering

Composite panel mould & trim tooling

Large 3 & 5 axis CNC machining capability

Assembly jigs inc complex mechanised assembly fixtures

Ground Support Equipment

Tool Installation

Tool try out - component / process proving

Engineering consultancy & tooling support worldwide

Kaman is committed to Continuous Improvement,

Lean Enterprise and Cost Reduction Initiatives,

a few of these are described below:

Lean Enterprise/Kaizen events

“5’s”

Set-up reduction,

Optimised material and process flows

Total Preventive Maintenance (TPM)

Implementation of Visual Workspace Management

Utilisation of advanced CNC equipment and techniques

CATIA V4 - V5 & Unigraphics

Secure FTP Protocols

STEP and IGES Translators

RTM (Real Time Machining)

CE Marking & Technical Files

Operator User Manuals

Concurrent & Reverse Engineering

In-house Design & Project Management

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KAMAN has over 22 yrs experience in the Design and Manufacture of aircraft tooling:

GE90 Nacelle Repair Jig Project Management

KAMAN Tooling Ltd have four Internationally experienced Project Managers, utilising Microsoft Project,

along with other various methods of reporting such as:

Five Box Reporting, RAG and SWIP Reports,

In order to support weekly project reviews with our customers outside of the UK, we also have:

Video conferencing

WEBEX capabilities

Past, Present & Commitment

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Examples of past and present programs include:

Embraer KC-390: Cargo Ramp Assembly line

Airbus A350: Fixed Leading Edge Mould Tools (Nickel Shell), Bird Strike Test Tooling,

Assembly Tools to facilitate Automation (Drilling & Riveting) – AGV Movement

Airbus A380: Wing skin Automated Shot Peen Fixtures

Airbus A320 – NEO: Fairings, Over & Under Wing Panels – Nickel Shell / Composite Moulds

CFM International LEAP-X (Nacelle Panels)

Airbus (UK): Next Generation Composite Wing Development Tooling

EADS Astrium: Satellite Assembly , Ground Test Equipment & GSE

Bombardier C-Series: Composite Wing Tooling

Lockheed Martin F35: Assembly Jigs, IFOD (Doors) ,Fuselage and Tail Plane

Bombardier Learjet 85: Main Cabin & Over Wing Emergency Exit Door , Component & Assembly Tooling

Bae Typhoon / Taranis: Assembly Jigs, Mould Tools (Invar – Nickel)

Gulf Stream G280: Winglet & Aileron Final Assembly Jigs

Rolls Royce A350 XWB: C-Frame Nacelle Handling Fixtures

KAMAN/Boeing A-10: Assembly - Wing Fatigue Upgrade Program)

Bell-Viper AH-1Z: Forward - Aft - Splice & Pylon Assembly Tooling

UK MoD: Engine Strip & Survey, Ground Support Equipment (Eurofighter, Tornado & Hawk)

Embraer KC-390 Cargo Ramp

KAMAN have been contracted to design and manufacture the cargo ramp production

assembly line, and provide Installation at the customers manufacturing facility

20 tool package consisting:

Assembly tooling

Transportation trolleys

Lifting frames

Onsite Installation

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The assembly line has been developed to operate as a pulse line,

in order to maximise build efficiency and encourage reduced takt time,

while creating an ergonomically safe operator environment

Automation Concept

Kaman Tooling were commissioned to design this conceptual robotic

drill and countersinking cell, working to a high volume pulse line

configuration with a minimal takt time requirement,

Universal palletised handling system:

Vacuum assisted holding fixtures

Vision Cam alignment

Lifting frames

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Drill & Countersink - Robotic cell

2013:

5m x 2.5m x 1.25m

Q4: 2013: Will see an increase in our 5 axis capability

20m x 3m x 1.5m

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3 & 5 Axis CNC Machining

Airbus A350

(FLE) Bird Strike

Test Piece - Mould & Impact Fixture

6m x 2.3m x 1.5m

Onsite access to 6 autoclaves: (largest - 13m x 3.125m)

Enabling full customer support:

- New Product Introduction (NPI)

- Process Development

Use of Helium Leak Detect System to certify and guarantee the

integrity of the mould surface:

- Nickel Shell

- Carbon Fibre

- Invar

- Steel

- Aluminium

- Tooling Board

- Medium Density Fibre Board

Mould Tooling

Airbus A380:

GLARE Test tool

(5m x 3m x 1m)

2.5m x 2.5m x 1m

Airbus A350:

FLE: (8m x 1m x 1m)

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Rout Tooling

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Airbus - Atlas

Wing / Root Fairing

Turnover Rout Fixture

5 Axis - Fully Sensored

KAMAN have manufactured a large range of rout tooling,

From simple bench hand rout fixtures, to complex 5 Axis tools comprising of integrated

sensors and vacuum cups, along with indexed sub-frames using Wixroyd type locators to

enable the accurate repeatability of operations in a pulse line environment of high volume

critical finish manufacturing,

Various materials used:

- Glass Reinforced Plastics

- Pre-Preg / Carbon Fibre

- Tooling Board

- Aluminium

Learjet 85

Multiple Loading Fixture

Learjet 85

Vacuum Drill & Rout

Airbus - A350

FLE- Rout Fixture

Multi-million tooling budget

Full project management

Design & make detail tooling, Sub-assembly

& Main assembly fixtures

Laser tracker & Installation of all tooling in

clean room conditions

Thru production calibration support

E3000 Satellite Project

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Satellite Test Equipment (Integrated laser positioning system)

Design partner

Manufactured in 8m modules (42m complete)

Delivered & Installed onsite at Airbus Broughton by our tool installation team

AIRBUS - A380

Wing Skin Shot Peen Fixtures

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AIRBUS - A350 (FLE):

Automated Drill-C’sk & Assembly Jigs

A350 (FLE) Mid – Outboard Spars

Each moveable work station is 8m x 3m x 2m

Air Guided Vehicle Compatible

Build to Print complete at KAMAN

Full onsite support and tool Installation

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AIRBUS - A350 (FLE):

Automated Drill-C’sk & Assembly Jigs

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A350 (FLE) Inboard Spars

Each moveable work station is 8m x 3m x 2m

Air Guided Vehicle Compatible

Build to Print complete at KAMAN

Full onsite support and tool Installation

Kaman Tooling is an ITAR approved company, and have long been involved in the design and manufacture of various

tooling packages in support of F35 Development & Production including all the In Flight Opening Doors - composite mould

and assembly:

Bae Systems (UK): for Lockheed Martin (Single Source Supplier - All Mould Tools)

Rear Fuselage - HTP - VTP

Invar Mould Tools,

Vacuum Router Tools

Bonding Fixtures

Final assembly Fixtures

Lifting Equipment

TERMA AS (Denmark) / Northrop Grumman:

Gun Pod Mandrel Tool

Invar Mould Tools,

Vacuum Router Tools

Bonding Fixtures

Final assembly Fixtures

Fokker Aerostructures (Netherlands):

All In Flight Opening Doors : CTOL - STVOL - CV

Invar Mould Tools,

Vacuum Router Tools

Bonding Fixtures

Final assembly Fixtures

EDM Ltd (United Kingdom):

Full scale (Replica) working doors – Training solutions

F-35: KAMAN Involvement

Company Restricted No Tooling pictures are available due to ITAR Restrictions:

C D F

G

B

A H

E

A. Lift Fan Upper

B. Auxiliary Air Intake

C. Lift Fan Exhaust

D. Roll Nozzle Ducts

E. Main Landing Gear

F. Lift Fan Lower

G. Nose Landing gear

H. In Flight Re-Fuelling

Ground Support Equipment

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GSE is a core part of Kaman Tooling’s business portfolio:

Bae Systems being our prime customer, KAMAN also manufacture bespoke:

Lifting,

Transportation

Handling solutions

Outboard Sensor

Protection

Canopy Stays

Landing Gear Locks

Canopy

Transportation

Protective Covers

Engine Handling

Eurofighter

Tornado

Hawk

Rolls Royce Trent 1000

Airbus A380

Bell AH-1Z

GSE: Handling Equipment – Engine & Airframe

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Trent XWB: Airbus A350

Nacelle Handling

Build to print:

Proof loading certified

Welding certified

CE Marked

Operator user manuals

GSE: Handling Equipment – Engine & Airframe

Company Restricted Eurofighter

Front Fuselage Transportation Stillage

GSE: Lifting Equipment

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Vacuum Assist Lifting

In house design – Build to print

Proof loading certified

CE Marked

Operator user manuals

ISO 14001

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(12m x 2.5m x 4m)

AIRBUS A380: IOFLE Transportation Trailer

Build to Print

Full project management.

Fabricated in house

GSE: Vac Formed & Rubber Covers

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All our GSE is designed and manufactured onsite to meet our customers expectations,

with all models & moulds made by our specialist patternmakers, and with final production

and kitting taking place in our dedicated cell.

Out–Board Sensors

Air Intakes

Internal Switches (Cockpit)

GSE: Kitting & Support Equipment inc Containerisation

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Flight Line Maintenance and Specialist Tooling:

Canopy Struts

Engine Bay Door Struts Canopy Transportation Single or

Twin

Fin Installation & Removal

Canopy Rigging Pins

Actuator

Installation & Removal

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AIRBUS - A320/321 (Rate Tooling):

Nickel & Composite Moulds

Project awarded to KAMAN as the preferred supplier, having manufactured the previous

5 sets of 44 mould tools, consisting:

32 Carbon Fibre & 12 Nickel Shell mould tools,

Fairings - Under & Over wing panels

Build to Print

Full project management.

All models, stage tooling etc re-furbished in-house, along with final production tooling

Onsite support (Malaysia)

KTL designed and developed the full suite of tooling for component

manufacture and final assembly along with developing manufacturing

processes in support of Kaman Composites.

Bombardier LJ85 PAX & OWEE Doors

Main Passenger

Entry/Exit Door

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Over Wing Emergency

Exit Door

Bell Helicopter AH-1Z Cabin

Kaman Tooling was responsible for the:

- Full In-house Design & Manufacture

FWD Fuselage & Pylon Production Tooling

137 Production Tools

12 Major Assembly Jigs inc Splice Fixtures

Onsite Installation KAMAN (Jacksonville FL)

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Canopy

Assembly Jig

Pylon Assembly

Breakout Fixture

This suite of tooling was manufactured in our UK facility - shipped to Jacksonville (USA), where it

was fully assembled and calibrated by our tool installation team prior to customer buy off

Aft Fuse

Assembly Jig

Kaman Tooling was responsible for the In-house Design and Manufacture of

the wing assembly jigs and fixtures for the flight control surfaces and the

onsite Installation at KAMAN (Jacksonville FL)

Leading Edge Assembly Jig (Port/STB)

BRG Install Assy Jigs (INBD / OUTBD)

LE Stage 1 Assy Fixture (Port/STB)

LE Stage 2 RMF Fixture (Port/STB)

LE Stage 3 Assy/ Checking Fixture (Port/STB)

Boeing A-10 Re-Wing

Company Restricted No Tooling pictures are available due to ITAR Restrictions:

This suite of tooling was manufactured in our UK facility - shipped to Jacksonville (USA), where it

was fully assembled and calibrated by our tool installation team prior to customer buy off

Gulfstream G280: Winglets

Kaman Tooling was responsible for the In-house

Design and Manufacture of the:

Mould tools (L/R)

5 Axis rout fixtures (L/R)

Sub & Final Assembly jig (L/R)

CMM Checking fixture (L/R)

Test Fixture (L/R)

The Winglet is a co-cure /co-bonded assembly consisting of several

individual carbon parts, Inner and Outer skins with a NOMEX

honeycomb core and manufactured in-house by KAMAN.

The Winglets are also capped with a protective polished Aluminum

leading edge

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Method 1 Approval (Direct to Line Delivery)

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Key Processes & Summary:

Design & Engineering

Project Management

Fabrication (inc Coded)

3 & 5 Axis Machining

Composite Manufacture

Assembly

Inspection

ISO 18001

ISO14001

AS EN 9100

BS EN 9001:2000

Kaman’s Unsurpassed Product Quality

Kaman has a comprehensive Quality Management System that is fully compliant with the standards and

specifications identified below, designed to ensure systematic controls are in place to guarantee

customer quality requirements are consistently met.

AS EN9100 Rev C Quality Management

ISO 14001 Environmental Management

ISO 18001 Health & Safety Management

The aforementioned certifications are a testament to the integrity of our systems and procedures and our

ability to provide aerospace tooling of the highest quality. Kaman’s Quality Assurance organisation, in conjunction with

our Manufacturing Engineering, Operations, Purchasing, and the other functional organisations, constitutes a

vital and effective team to ensure that our customers are provided with the optimum in product quality,

integrity, timely delivery, and continued customer support.

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KAMAN Tooling Investment Strategy

(Artists Impression) HEXAGON Delta Slant: 6.3m

CORREA Anayak: 20m x 3m x 1.5m

Having recognised the changing requirements in aircraft design - manufacturing and assembly processes,

we have now committed to some significant capital investments in order to allow us to adapt, to meet,

and have the capability and capacity exceed these future challenges,

We have approached this by committing to a second 60,000sq/ft facility located within the new

Aerospace Supply Park in Burnley (UK), and by procuring additional new equipment including:

20m 5axis Correa Anayak CNC machine

6.3m Hexagon Delta Slant CMM

This investment is further testament to the continued support and belief in KAMAN Tooling Ltd

by the board of KAMAN Corporation and underpins our strategy of growth and increased capabilities,

Major Client List:

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Andrew Rourke - Sales & Marketing Manager

Tel: 00 44 (0)1254 874 977

Mobile: 00 44 (0) 7912 540370

E-mail: [email protected]

KAMAN Tooling Ltd

India Mill, Darwen

Lancashire

BB3 1AD

United Kingdom

Please visit us at:

Hall 3 – Stand D118