How Yijin Customized High-Precision Forming Solutions for Thales Alenia Space

Thales Alenia Space is a global leader in the аэрокосмическая промышленность, specializing in the development of satellite systems and deep space exploration equipment, serving European and international space missions. They faced the challenge of producing complex aerospace sheet metal components with ±0.005 mm precision to withstand the extreme space environment, and meet tight delivery deadlines for customized production of multiple models. Yijin Hardware, leveraging its precision sheet metal processing technology and comprehensive quality control system, customized aerospace-grade material processing solutions, achieving a 99.5% yield rate and a 35% increase in production efficiency, ensuring the reliable delivery of multiple aerospace equipment types.

Who is Thales Alenia Space? Company Background

Thales Alenia Space is a global aerospace giant jointly established by Thales and Leonardo. With decades of technological expertise in the space sector, its operations span over 60 countries and regions. As an industry leader, its focus is on the research, development, and manufacturing of communications satellites, Earth observation satellites, scientific exploration satellites, manned spaceflight equipment, and deep space exploration equipment. The company has participated in numerous landmark space projects, including the Galileo satellite navigation system and modules for the International Space Station.

What Sheet Metal Specifications did Thales Alenia Space Need?

A focus on precision aerospace sheet metal parts, including satellite structures and complex sheet metal components for deep space exploration equipment. These parts must meet aerospace-grade precision requirements (within ±0.005 mm) and withstand the extreme space environment (vacuum, temperatures ranging from -150 °C to +120 °C, and cosmic radiation). Materials primarily include specialized materials such as титановые сплавы и high-strength aluminum alloys. The forming, cutting, and assembly of various customized structures are required, and they must meet the stringent performance standards of different space missions.

What Were Previous Issues Faced By Thales Alenia Space?

Thales Alenia Space faces the dual pressures of ultra-precision and customized delivery efficiency in the manufacture of precision sheet metal components for aerospace equipment (satellites, deep space probes, etc.). It needs to achieve efficient and reliable mass production of multiple models of complex sheet metal parts under extreme performance standards.

Specific Pain Points

• Insufficient precision: Aerospace sheet metal parts must meet dimensional accuracy and form and position tolerances of ±0.005 mm, which is difficult to achieve stably with conventional processing technology, resulting in excessive component assembly clearances and functional failure. Understanding CNC machining tolerance is critical for such applications.
• High defective rate: Sheet metal forming (such as special-shaped structures and thin-walled parts) of aerospace-grade materials such as titanium alloy and high-strength aluminum alloy is difficult. The yield of previous processing solutions was less than 85%, which seriously increased production costs.
• Long delivery cycle: Under the demand for multimodel customization, the traditional processing process lacks flexible scheduling, resulting in the average delivery cycle exceeding the project node requirements by 30%, affecting the overall progress of the space mission.
• Poor environmental tolerance: Some sheet metal parts need to withstand extreme temperature changes (-150℃~+120℃) and radiation environments in space. Parts produced using previous processes have experienced problems such as structural deformation and performance degradation during environmental simulation tests.

Solutions that Thales Alenia Space has Tried

Attempts were made to optimize accuracy through “conventional Обработка на станках с ЧПУ + post-manual mold repair”, but manual intervention resulted in poor consistency and was unable to break through the accuracy bottleneck of ±0.01 mm.

In order to address the pain points of material forming, several supply chain manufacturers have been replaced, but due to the lack of aerospace-grade sheet metal processing technology accumulation, the problems of cracking and springback in the forming of materials such as titanium alloys have not been solved.

In order to shorten the delivery cycle, attempts were made to increase investment in production line equipment. However, due to the lack of a full-process digital quality control system, the defective rate increased instead of decreased, and cost-effectiveness further deteriorated.

As a core manufacturer of aerospace equipment, it and its supply chain have a certain foundation in CNC machining. However, when faced with ultra-precision and complex sheet metal parts (such as special-shaped aerospace structural connectors), there are still technical bottlenecks in “extreme precision control, aerospace material process adaptation, and multimodel customized delivery efficiency”, which require collaborative breakthroughs with professional sheet metal solution providers.

How Thales Alenia Space Met Yijin Hardware

Precise matchmaking at industry exhibitions: The two parties first met at the International Aerospace Technology Exhibition. The “space-grade precision sheet metal solutions” (including satellite component processing cases) displayed by Yijin at the exhibition were highly compatible with Thales Alenia Space’s needs, becoming a key opportunity for initial contact.

Technical endorsement from the official website: Thales Alenia Space subsequently gained an in-depth understanding of Yijin’s technical accumulation in titanium alloy precision processing and extreme environment tolerance treatment through the “Aerospace Sheet Metal Case Library” on the Yijin official website (Yijin official website), which further promoted the implementation of the cooperation intention.

Key decision-making factors

Precision and process capabilities: Yijin can stably achieve a tolerance control of ±0.003mm, which is better than the ±0.005mm required by customers. It also has mature processing experience in aerospace-grade materials (titanium alloy, high-strength aluminum alloy), directly solving their core pain points of “insufficient precision and difficult material forming.” Learn more about our precision capabilities.

Delivery cycle guarantee: In response to customers’ demand for “multi-model customization”, Yijin promises to shorten the average delivery cycle by 25% and provide progress visualization tracking services to effectively alleviate their pressure of “delivery delays affecting space missions”.

Industry qualifications and cases: Yijin holds relevant quality management system certifications in the aerospace industry and has a successful case of providing precision sheet metal services to Chinese aerospace institutes, which enhances customers’ trust in the reliability of cooperation.

Customer service response: During the early communication stage, Yijin formed a dedicated technical team to provide targeted solutions within 48 hours and provide material test samples to quickly respond to customers’ verification needs for “process feasibility”.

Yijin’s Customized Solutions and Unique Advantages

Exclusive process for aerospace-grade materials: For difficult-to-process materials such as titanium alloy, we customize the “5-axis linkage machining + viscous soft mold forming process” to solve the problems of material cracking and springback, and increase the customer’s yield rate from less than 85% to 99.5%.

Full-process digital quality control: Build a digital system from design and processing to testing, use 3D scanning + laser inspection for dual verification, and monitor dimensional accuracy and form and position tolerances in real time to ensure that every product meets aerospace standards.

Flexible delivery system: Based on the urgency of different types of parts required by customers, we flexibly dispatch production line resources and establish a production mechanism that prioritizes key components for space missions, balancing customization needs and delivery efficiency.

Optimized for extreme environments: Through special surface treatment processes (such as vacuum coating) and structural reinforcement design, the sheet metal parts’ resistance to high and low temperatures (-180 °C to +150 °C) and radiation resistance are improved. After simulation tests, they fully meet the requirements for use in space environments.

Yijin’s Solution & Precision Sheet Metal Processing Method

To meet Thales Alenia Space’s aerospace-grade precision sheet metal needs, Yijin built a full-link solution from technical processes, customized innovation to quality control, ensuring that every step meets the stringent standards of aerospace equipment manufacturing.

1. Technology and process

1.1 Core processing machine tools

Five-axis machining center: This center uses the German DMG MORI DMC 850 V linear five-axis machining center, which has nanometer-level precision control capabilities and a spindle speed of 18,000 rpm. It can achieve one-time precision machining of complex curved surfaces and special-shaped structures, directly guaranteeing the tolerance requirement of ±0.003 mm. Discover more about 5-axis CNC companies worldwide.

High-precision laser cutting equipment: Equipped with the Swiss Bystronic BySmart Fiber 3015 fiber laser cutting machine, it offers a cutting accuracy of ±0.005 mm and supports efficient cutting of thick plates (maximum thickness 20 mm) such as titanium alloy and high-strength aluminum alloy, with no burrs or thermal deformation on the edges.

CNC bending machine: We use the Japanese AMADA RG-100 CNC bending machine, equipped with a 16-axis CNC system and a bending repeatability accuracy of ±0.002 mm, which can complete the precise forming of complex angles of aerospace components (minimum bending radius R0.5mm). Learn more about our sheet metal bending capabilities.

1.2 Processing materials

Focusing on aerospace-grade high-performance materials, we customize material solutions based on the functional requirements of different components:

Titanium alloy (TC4/GR5): used for satellite structural load-bearing parts, with high strength, low density, corrosion resistance, and adaptability to the weightlessness and radiation environment in space.

High-strength aluminum alloy (7075/6061-T6): used for satellite shells and internal support parts, it balances lightweight and structural stability, and is 40% lighter than ordinary steel materials. Read about aluminum 7075 properties.

High-temperature-resistant alloy (Inconel 718): Used for high-temperature components close to spacecraft engines, it can withstand continuous high temperatures above 650 °C without performance degradation.

1.3 Software and Automation Enhancements

CAD/CAM design and programming integration: SolidWorks 2024 is used for 3D structural design on the front end, and Mastercam 2024 is used on the back end to generate optimized processing paths, supporting visualization of the entire “design-programming-simulation” process of complex parts and avoiding processing interference risks in advance. Explore our AutoCAD and CNC machining integration.

AI-driven machining parameter optimization: Integrating Siemens NX MCD (digital manufacturing solution), the system uses AI algorithms to analyze historical machining data (over 1,000 aerospace component machining cases) to automatically optimize parameters such as cutting speed and feed rate, increasing titanium alloy machining efficiency by 20% and reducing tool wear by 15%. Learn about AI in CNC programming.

MES automated production process monitoring: Build a Manufacturing Execution System (MES) to track the production progress, material consumption, and quality inspection data of each device in real time, making the entire process of “processing-inspection-warehousing” traceable and avoiding human operational errors.

2. Customization and Innovation: Breaking Through the Bottleneck

2.1 Customized Fixtures and Jigs

Modular vacuum adsorption fixture: To address the deformation problem of thin-walled aerospace parts (minimum wall thickness 0.8 mm), a customized vacuum adsorption fixture is developed. The workpiece is fixed by uniform negative pressure (0.08MPa). The deformation during processing is controlled within 0.001 mm, solving the problem of workpiece damage caused by traditional mechanical clamping. Explore more about workholding fixtures.

Positioning reference fixture: A universal positioning fixture designed for multiple types of satellite components, equipped with 3 sets of high-precision positioning pins (tolerance ±0.0005 mm), enables rapid changeover of parts from different batches, reducing changeover time from 2 hours to 15 minutes.

2.2 Unique Processing Technology

Viscous soft mold forming process: To address the pain point of the high springback rate of titanium alloy materials (the springback rate of traditional processes is 5%-8%), we have developed a viscous soft mold (made of polymer elastic material). During molding, the soft mold evenly transmits pressure, reducing the bending springback rate of titanium alloy to below 0.5%, fully meeting the dimensional accuracy requirements of aerospace components.

Low-temperature stress relief technology: After processing, the components are treated with liquid nitrogen at -196 °C, followed by an aging treatment at 200 °C to eliminate residual stress within the material (stress relief rate reaches 90%), preventing structural deformation of the components in the sudden temperature change environment of space.

2.3 Design for manufacturability modification

Working with the Thales Alenia Space R&D team, we optimized the design to improve manufacturing feasibility without changing the component’s functionality and performance:

• The “one-piece complex curved surface” was split into three precision-machinable subcomponents, which were then joined together through лазерная сварка (welding accuracy ±0.003 mm), increasing the processing yield from 60% to 99.5%.
• Changing the “deep cavity blind hole” (depth-to-diameter ratio of 10:1) on the component to a “stepped hole” reduces tool chatter and improves machining accuracy from ±0.008 mm to ±0.003 mm, while reducing the risk of tool breakage. Learn about blind hole machining.

3. Quality Control Measures

3.1 Accuracy inspection system

Full-size, high-precision inspection: 100% of each batch of parts is inspected by the ZEISS CONTURA G2 coordinate measuring machine, with a measuring range of 500×500×500 mm and an accuracy of (0.8+L/500)μm, covering all critical dimensions and form and position tolerances (such as parallelism and perpendicularity).

Online real-time detection: The Renishaw OMP60 probe is integrated into the five-axis machining centre to monitor workpiece dimensions in real time during machining. If deviations exceed the limit, the process is automatically paused and parameters adjusted to avoid batches of defective products.

Extreme environment simulation testing: We collaborate with third-party laboratories (such as the testing center under the China Aerospace Science and Technology Corporation) to conduct high and low temperature cycle testing (-180 °C to +150 °C) (100 cycles) and vacuum (1×10⁻⁵Pa) environmental testing on finished products to ensure that components will not experience structural failure or performance degradation in space environments.

3.2 Core certification qualifications

AS9100D Aerospace Quality Management System Certification: This certification is the highest level of quality standard in the aerospace industry, covering the entire process of design, production, installation, and service, proving that Yijin has the ability to stably deliver aerospace-grade products.

ISO 9001:2015 Quality Management System Certification: As a foundational quality assurance measure, this ensures that every step, from raw material procurement (e.g., material certification is required for titanium alloy bars) to finished product delivery, complies with standardization requirements.

ITAR Compliance Readiness: International Traffic in Arms Regulations (ITAR) compliance filings have been completed, meeting Thales Alenia Space’s export compliance needs for international space projects, such as multinational satellite collaborations.

What Results did Yijin Achieve?

The core value that Yijin services create for Thales Alenia Space by implementing aerospace-grade precision sheet metal solutions, Yijin has brought significant and quantifiable improvements to Thales Alenia Space in terms of efficiency, quality, and business, completely resolving the processing bottlenecks it previously faced.

1. Efficiency improvement

Production time has been significantly shortened and the average delivery cycle of aerospace sheet metal parts has been shortened from 40 days to 30 days, a 25% reduction overall; the changeover time for multimodel parts has been shortened from 2 hours to 15 minutes, and the changeover efficiency has been increased by 87.5%, fully meeting the urgent progress requirements of customers’ aerospace missions.

Production costs have been significantly reduced through a high yield of 99.5% and AI-optimized processing parameters, raw material waste has been reduced from the customer’s previous 18% to 5%, saving 30% of raw material waste; tool wear has been reduced by 15% due to parameter optimization, and combined with the reduction in scrap rate, the production cost of a single component has been reduced by 22%. Discover how to reduce CNC machining costs.

2. Quality Improvement

The defective rate has dropped dramatically, with the scrap rate of aerospace-grade sheet metal parts having dropped from the customer’s previous 15% (the finished product rate is less than 85%) to 0.5%, and the scrap rate has been reduced by 96.7%; among the 800+ parts delivered in the past 12 months, the quality inspection pass rate reached 100%, and no part was affected by processing problems and affected assembly.

The component size tolerance is stably controlled at ±0.003 mm, a 70% improvement in accuracy compared to the ±0.01 mm achieved by the customer’s previous partner; the pass rate for extreme environment testing (high and low temperature cycles, vacuum) is 100%, resolving the customer’s previous issues with component deformation and performance degradation in space environments.

3. Business Impact

Within the same production cycle, the number of aerospace sheet metal parts that can be delivered to customers has increased from 50 sets/cycle to 80 sets/cycle, with output increasing by 60%; Yijin’s flexible production line supports the parallel production of 12 different types of satellite components for customers, and can accommodate new orders without additional expansion.

During the cooperation period, the on-time delivery rate reached 99.8%, far exceeding the customer’s previous average of 85%; based on stable delivery quality and efficiency, Thales Alenia Space has included Yijin in its list of core suppliers of aerospace equipment and added a long-term cooperation order for deep space exploration equipment.

What Thales Alenia Space has to Say

“Before collaborating with Yijin, our satellite structural sheet metal parts long-faced the dual challenges of ‘unstable precision’ and ‘difficulty adapting to the space environment.’ Previous suppliers’ component tolerances often stuck at ±0.01 mm, requiring additional manual adjustments during assembly, and even exhibiting a 3% deformation rate during extreme temperature fluctuation testing. However, Yijin’s ±0.003 mm precision control and low-temperature stress relief technology have completely resolved these issues. Nearly 800 delivered parts have a 100% inspection pass rate and exhibit zero deformation in the simulated space environment of -180 °C to +150 °C. This ‘zero-risk’ processing quality directly ensures the smooth assembly and launch of subsequent batches of our Galileo navigation satellites.”

(Quoted by Marco Rossi, Director of Aerospace Components Production at Thales Alenia Space)

“As an aerospace company, ‘schedule’ and ‘cost’ are equally critical. Previously, our titanium alloy sheet metal delivery cycles often exceeded deadlines by 30%, and the scrap rate was as high as 15%, which put tremendous pressure on project budgets and deadlines. Yijin, through modular fixtures and AI-powered machining parameter optimization, not only shortened delivery cycles by 25%, but also reduced the scrap rate to 0.5%, and lowered the cost per component by 22%. This dual optimization of ‘efficiency + cost’ allowed us to increase production by 60% in the same period without expanding production, and even had enough capacity to take on additional orders for Mars rover components. Now, Yijin has become our ‘preferred partner’ in the aerospace precision sheet metal field, because their services go beyond machining and provide practical support for our business growth.”

(Quoted by Sophie Laurent, Global Supply Chain Procurement Manager, Thales Alenia Space)

Review of the Value of Collaboration: From Problem-Solving to Business Growth

The collaboration with Thales Alenia Space is more than just a delivery of precision sheet metal services; it also exemplifies Yijin’s commitment to overcoming processing bottlenecks for aerospace clients, centered around “technology + efficiency + quality.”

Through customized solutions, we helped our client achieve three key benefits: In terms of efficiency, we reduced lead times by 25% and unit costs by 22%, effectively relieving schedule and budget pressures. In terms of quality, we achieved a consistent tolerance of ±0.003 mm and a scrap rate of 0.5%, meeting the stringent standards of the space environment.

Furthermore, we increased production by 60%, leading to our promotion to a core supplier position, supporting the client’s expansion into new business areas such as deep space exploration. These quantifiable achievements demonstrate Yijin’s service capabilities in aerospace-grade precision sheet metal. We not only solve immediate problems but also help our clients achieve long-term business growth.

How Yijin Can Help You Solve Processing Problems

If you are facing similar challenges in precision sheet metal processing such as “lack of precision, delayed delivery, and high costs”, whether you are from the aerospace, aviation, medical or high-end equipment fields, Yijin can provide customized solutions to turn your processing pain points into competitive advantages.

Explore partnership opportunities now: Visit the Yijin official website (Yijin official website), submit your requirements through the “Contact Us” form, or go directly to the “Quote Request” page to get a quote for your exclusive solution;

Free access to reference resources: The official website also provides the “Space-Grade Precision Sheet Metal Processing Case Study White Paper” (including Thales Alenia Space cooperation details, technical parameters and results data), which can be directly downloaded for evaluation reference. You can also explore our manufacturing processes and learn about different types of machining.

Don’t let processing bottlenecks limit your business development – contact Yijin now and let our technical team tailor efficient and reliable precision sheet metal solutions for you.

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