From Classroom to Workplace with VTI Brugge

Today's students are tomorrow's professionals. In the rapidly changing world of technical industries, helping young people prepare for their future careers isn’t just a good idea, it’s essential. This belief forms the foundation of our longstanding partnership with VTI Brugge and drives the Workplace Learning program, a practical bridge between education and the professional world.

What is VTI Brugge?

VTI Brugge (Vrij Technisch Instituut Brugge) is a technical secondary school in Bruges, Belgium. The school focuses on practical technical education for students aged 12-18, teaching skills in mechanics, electronics, construction, and information technology. Schools like VTI play an important role in Belgium by preparing students either to enter the workforce directly or continue with higher education.

Our Growing Partnership

BMT Aerospace has been working together with VTI Brugge for quite some time. Over the years, this partnership has grown to include a range of activities. We take part in the school’s open house events and regularly welcome students for guided tours of our shop floor. A key part of this cooperation is the Workplace Learning program, which we introduced a few years ago to give students real-life experience in a professional environment.

A Closer Look at Workplace Learning

This program brings students to our Oostkamp site for real-world learning experiences. Each visit follows a clear and effective format:

1. Morning Theory Sessions: Students start with classroom-style lessons taught by BMT Aerospace team members. These sessions cover key concepts and technical knowledge needed in aerospace manufacturing, including topics such as sector gear technical requirements and production methods, machining tools management, geometric dimensioning and tolerancing, and reading technical drawings.
2. Hands-on Practice: After learning the theory, students move to our shop floor where they complete practical assignments under expert guidance. This hands-on experience helps them apply what they've just learned as they perform activities like shrink fit tooling, flatness and height measurements, thermal treatment, and hardness testing.

This combination of theory and practice helps students understand both the "why" and "how" of aerospace manufacturing. They learn industry standards, see how quality processes work, and gain practical skills that complement their school education.

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The Impact of Workplace Learning

Workplace Learning has many benefits. It gives students the chance to experience a real working environment before choosing their career path. Because they work with machines and technology not usually available at school, they develop practical skills that employers value. It also allows them to meet professionals who can offer advice. Additionally, it’s a great way to introduce students to BMT Aerospace and possibly inspire them to start their careers with us.

Preparing for the Future

There is a strong and ongoing demand for technical talent, which isn’t likely to change anytime soon. That’s why it’s so important for young people to gain early experience in a real working environment. Through Workplace Learning, students discover their strengths, learn new skills, and build confidence in a technical setting. The partnership between BMT Aerospace and VTI Brugge shows how schools and companies can work together to support and guide the next generation.

Making 3D-printed parts shine: The FITFAME project

The "Finishing Technologies for Additively Manufactured Complex Parts" (FITFAME) project is part of the General Support Technology Programme (GSTP), sponsored by ESA (European Space Agency).

The Programme focuses on leading-edge technologies that are not yet space-ready and develops them for future missions. These missions aim to help us discover the Universe, understand our environment, improve navigation, educate, and save lives.

It brought together BMT Aerospace, SABCA, CRM Group, APworks, and Chimiderouil to tackle the rough surfaces often found on 3D-printed metallic parts.

Improving Surface Finishing for Aerospace Applications

Additive Manufacturing (AM), or 3D printing, is amazing for creating complex shapes and reducing material waste. However, the parts often come out with rough surfaces that need extra finishing to meet aerospace standards. The FITFAME project aimed to improve these finishing technologies, making AM parts more suitable for high-performance use.

The main goal was to advance finishing technologies from lab-tested solutions (Technology Readiness Level 4) to prototypes used in real-world conditions (Technology Readiness Level 5 – 6). They reviewed existing surface technologies, selected specific case studies, developed and tested complete AM processes, and benchmarked results against conventional methods.

The project successfully improved the handling of complex 3D-printed parts using advanced techniques like Laser Powder Bed Fusion (LPBF) with Scalmalloy and Electron Beam Melting (EBM) with Ti6Al4V. These advancements pave the way for better performance and efficiency in aerospace applications.

Use Cases and Testing

Two specific use cases were selected:

1. Hydraulic Manifold for Ariane 6 Thrust Vector Actuation System (TVAS)

This component was redesigned using LPBF technology to improve hydraulic performance while reducing weight by up to 10%. Various finishing techniques were tested including abrasive flow machining; chemical polishing; electrochemical polishing; DLyte™, Coolpulse™, MMP technology™ processing. The testing campaign showed significant improvements in hydraulic performance compared to machined counterparts.

2. Exit Ring Gear for Launcher’s Steering Fin Actuator Gearbox

The second use case focuses on a reusable launcher's steering fin actuator gearbox. The FITFAME project aimed to produce the output ring gear through additive manufacturing, achieving a significant weight reduction compared to conventionally machined equivalents.

Titanium was selected for its excellent weight reduction potential. However, it presents challenges due to lower stiffness and typically poor tribological performance. To address these issues, a tailored geometrical redesign—achievable only through additive manufacturing—was implemented to compensate for the material's shortcomings.

The manufacturing sequence began with producing a near-net shape blank using Electron Beam Additive Manufacturing (EBAM). Only the interfaces and gear teeth were machined, utilizing state-of-the-art skiving processes. Various surface finishing techniques such as corundum blasting, chemical polishing, stream finishing, and high-energy polishing were employed to enhance the quality of remaining surfaces. Through trials on coupons and full-size parts, valuable data was gathered regarding these processes' capabilities.

Finally, a case hardening heat treatment was applied before subjecting the components to mechanical strength performance testing. Despite titanium's inherent limitations for gear applications, satisfactory mechanical performance was achieved thanks to meticulous design and an end-to-end developed manufacturing process.y

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Benefits & Next Steps

The benefits realized from finished complex AM components include:

• Performance improvements on additively manufactured manifolds over conventional counterparts, showing better bandwidth and lower hydraulic resistance, resulting in up to 10% weight savings.
• Satisfactory performances observed among additively manufactured ring gears, achieving acceptable functionalities despite using titanium as the chosen material.

Next steps involve completing flight qualification campaigns for the AM-based hydraulic manifold. This is in preparation for engineering modifications within Ariane's thrust vector actuation system. Additionally, integrating REACH-compliance requirements throughout the involved processes is also a priority.

Conclusion

The FITFAME project has made great progress in improving additive manufacturing (3D printing) for creating complex parts. It tackled the problem of rough surfaces on these parts, making them smoother and cleaner. This improvement helps the aerospace industry adopt 3D printing more widely, leading to better performance and efficiency. For the ring gear use-case, the next step has to address improved heat treatment distortion control along with dynamic and functional performance testing.

The advancements from this project pave the way for future innovations in aerospace technology.

BMT Aerospace’s Smart Factory Revolution: Connecting Machines for a Greener Future

At BMT Aerospace, we're not just keeping up with the times; we're leading the charge into the future with our IIOT-connected-MES project. Imagine a factory where every machine is interconnected, sharing data in real-time to optimize operations. This is the essence of our project. We're embarking on a journey through the six phases of Industry 4.0, aiming to create a fully autonomous manufacturing environment.

Why are We Undertaking This Project?

Continuous improvement

Our primary goal is to boost product quality and operational intelligence. By connecting machines and systems through a centralized network, we can gather and analyze real-time data to predict maintenance needs, minimize downtime, and extend equipment lifespan. This proactive approach enhances our ability to make data-driven decisions, leading to higher standards of productivity and quality.

A more sustainable approach

Plus, we're also committed to sustainability. we reduce waste and energy consumption, aligning with global efforts to combat climate change. As machinery operates more efficiently and with less frequent interruptions. Additionally, smart sensors monitor energy usage across the factory floor, allowing for dynamic adjustments that conserve power during low-demand periods. This interconnected ecosystem supports a sustainable manufacturing process that aligns with global efforts to combat climate change

But how?

An ambitious project like this isn’t set up in a week. That is why in order to reach our goals, we’re working in phases.

1. Computerization: Enhancing repetitive tasks with isolated technologies.
2. Connectivity: Integrating previously isolated information technologies.
3. Visibility: Using sensors to collect real-time data across various operations.
4. Transparency: Analyzing data to understand the root causes of issues.
5. Predictive Capacity: Creating models to predict future scenarios and reduce unexpected events.
6. Adaptability: Enabling the factory to make autonomous decisions based on real-time data.

As a part of the first phases, we’re currently prioritizing two main objectives:

1. Building a Manufacturing Execution System (MES): Using the SAP API, we'll create a copy of relevant planning data in the SQL database of the IIOT hub. Operators can report job completions, which are then communicated back to SAP.
2. Creating Machine Activity Visibility: By using different sensors to measure power, vibrations, … , we'll visualize machine uptime on a dashboard, comparing planned data with actual working hours and measured machine activity.

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Implementation at BMT Aerospace

Our implementation strategy focuses on collecting critical information from three primary sources within the shop floor environment: operators, machines, and sensors. These three sources each have their own unique point of view and data to share. The Manufacturing Execution System (MES) back-end operates on a central gateway while edge devices installed locally gather and pre-process this data. This architecture optimizes data collection processes by minimizing transfers and reducing delay.

Data Storage and Analysis Framework

To effectively store and analyze data, our Industrial Internet of Things (IIOT) platform incorporates a combination of MQTT brokers (servers that manage communication between clients in a publish-subscribe messaging model), historian databases, and relational databases. This robust setup empowers us to monitor machine statuses accurately, predict potential faults proactively, and optimize operations using both real-time insights as well as historical trends.

The Power of Digital Twin Technology

In addition, we are also developing a digital twin—a virtual replica mirroring our physical systems' behaviors. This cutting-edge tool allows us to simulate scenarios, test various changes in manufacturing processes before actual implementation, predict outcomes accurately—and ultimately make informed decisions that enhance productivity while optimizing efficiencies across operations.

A smarter future

The IIOT-connected-MES project is a crucial part of BMT Aerospace's journey towards becoming a smart factory. By connecting our machines and leveraging advanced data analysis, we aim to enhance our manufacturing processes, reduce energy consumption, and improve product quality.

The Critical Importance of Weight in Aviation

The Critical Importance of Weight in Aviation

In aviation, weight is a crucial factor that significantly impacts the safety and performance of flights. One of the critical scenarios where weight becomes a focal point is during an overweight landing.

What is an overweight landing?

An overweight landing is defined as a landing made at a gross weight exceeding the maximum design (i.e., structural) landing weight for a particular aircraft model.

Description: There are situations, such as an engine failure, that may necessitate an airplane to land shortly after takeoff. In such cases, the pilot faces two primary options:

1. Land at a weight considerably above the maximum design landing weight: This option reduces the time spent in the air but may cause further damage to the aircraft and increase the risk of a runway excursion.
2. Reduce the weight before landing:
   This can be achieved in two ways –
   Execute a holding pattern to burn fuel: This method is closer to normal operations but requires the aircraft to remain airborne longer.
   Dump (jettison) fuel: This allows for a quicker landing within operational limits but may impact other aircraft or people on the ground.

Things pilots need to consider before an overweight landing

Regulatory: Generally, the maximum landing weight is an operational limitation that must be adhered to. However, deviations are permissible in the interest of safety, such as:

• A malfunction rendering the aircraft unairworthy.
• A situation where an expeditious landing reduces exposure to a hazard.
• A scenario requiring immediate medical attention.

Safety: Reducing the aircraft's weight requires additional time, increasing the risk of further deterioration of the situation. Conversely, an overweight landing reduces performance margins.

Ecological: Dumping fuel is generally undesirable below 5000-6000 feet, as the fuel may not evaporate before reaching the ground.

Airplane Structural Capability: While the maximum landing weight is an operational limitation, aircraft components, especially the landing gear, are designed to withstand much higher loads than those encountered during typical landings.

Airplane Performance Capability: The Aircraft Flight Manual (AFM) typically provides landing performance data at weights significantly above the maximum design landing weight. Pilots must balance maximum braking application with the available landing runway to avoid exceeding brake energy limits.

Automatic Landings: While automatic approaches can be attempted, it is generally recommended that landings be performed manually.

Inspection Requirements: A special inspection is usually required after an overweight landing, regardless of how smooth it was. Additional maintenance or repair actions may also be necessary.

While all three procedures (burn fuel, dump fuel, land overweight) are considered safe, it is the pilot's responsibility to assess the factors and choose the optimal solution for the specific situation.

Additive Manufacturing and Weight Reduction:

At BMT Aerospace, we are involved in projects that help set the standard for additive manufacturing (AM) in the future. AM has shown its ability to reduce the weight of manufactured parts significantly, which could be a huge benefit for the aerospace industry.

By leveraging AM technologies, we can produce lighter components without compromising on strength and durability. This weight reduction is essential for improving fuel efficiency, enhancing aircraft performance, and ensuring safer flights. Our commitment to innovation and advanced manufacturing techniques positions us at the forefront of the aerospace industry, driving progress and setting new benchmarks for the future.

ProGRAM JIP phase 3: AM and sustainability

The ProGRAM Joint Industry Project (JIP) is an ambitious initiative aimed at establishing and refining guidelines and industry standards for the application of metal components produced through additive manufacturing (AM) within the energy and maritime sectors. Since its inception in 2018, this project has engaged a consortium of over 20 companies spanning the entire supply chain. One of its significant achievements includes the development and continuous enhancement of the DNV standard DNV-ST-B203, which governs the qualification and production of parts using various AM technologies.

Phases of ProGRAM JIP

The latest phase, known as ProGRAM JIP Phase 3, started in May 2022. This phase concentrated on several critical areas:

1. Development of Guidelines for Part Families: Establishing comprehensive guidelines tailored to different part families to ensure consistency in quality.
2. Design for Additive Manufacturing: Creating standardized methods that facilitate design optimization specifically for AM processes.
3. Environmental Impact Assessment: Introducing a standardized approach to estimate and report on the environmental impact of AM compared to conventional manufacturing methods.

To validate these advancements, six real-life use cases were employed to verify both the quality and sustainability credentials of AM-produced parts, one of them being the TX Seal in which BMT Aerospace contributed.

BMT Aerospace's Contributions

BMT Aerospace's contributions to ProGRAM JIP Phase 3 are exemplified through our involvement in producing a TX Seal as part of a joined effort with OneSubsea (formerly Aker Solutions) and the National Manufacturing Institute Scotland (NMIS). The TX Seal is a metal-to-metal sealing element used to form barriers against well fluids, hydraulic fluids, and chemicals.

Several reasons justified selecting Additive Manufacturing (AM) for this part:

• Shortening production lead times
• Improving quality over conventionally forged parts
• Accommodating a large part family with sizes ranging from 1” to 14”
• Reduced material consumption, less raw material to keep in stock

BMT Aerospace played a significant role in enhancing both production efficiency and quality improvement for the TX Seal within ProGRAM JIP Phase 3. In addition, we were an important contributor for destructive and non-destructive inspections.

Focus on Sustainability in AM

One key area explored by ProGRAM JIP Phase 3 was sustainability—a crucial factor given today's emphasis on reducing industrial carbon footprints. The project identified that while AM can offer notable sustainability benefits, these are not universally guaranteed across all scenarios. Several factors influence these outcomes:

• Type of AM Technology: Different technologies have varying levels of efficiency and environmental impact.
• Material Used: The choice of material plays a significant role in determining overall sustainability.
• Energy Mix at Production Location: The source of energy used during production significantly affects CO2 emissions.
• Design Optimization: Efficient designs can reduce material usage and waste.
• Functional Performance: Ensuring that parts meet or exceed performance standards without unnecessary resource expenditure.

To aid in this assessment, an AM sustainability calculator was utilized to compare CO2 emissions between AM-produced parts and those manufactured through conventional means. Additionally, guidelines were proposed for objectively calculating and reporting carbon footprints specific to AM components.

Conclusion

The ongoing work under ProGRAM JIP underscores its commitment to advancing additive manufacturing within critical industries by providing robust standards that enhance both quality assurance and environmental responsibility. As we move forward, such initiatives will be pivotal in driving sustainable innovation across diverse industries.

BMT Aerospace Belgium Celebrates Remarkable Safety Record

BMT Aerospace Belgium has achieved an extraordinary milestone in workplace safety. For 2000 consecutive days, dating back to December 10, 2018, the Belgium plant has proudly maintained a record where no employee has missed more than a full day of work due to a work-related accident on site. This impressive streak underscores the company’s unwavering commitment to creating and nurturing a culture where safety is paramount.

Our Belgium plant’s dedication to safety is not just a policy but a core part of its identity, woven into the very fabric of daily operations. This accomplishment is a clear reflection of the collective efforts of every team member who consistently prioritizes a secure and healthy work environment.

This mindset has resulted in a number of small and big adjustments on the premises that contribute to a safe environment. Below you can find a few examples of many implemented in the plant.

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As we celebrate this significant achievement, we extend our heartfelt congratulations to the entire team at BMT Aerospace Belgium. It is through your diligence and commitment that we continue to uphold the highest standards of safety, as outlined in our Code of Conduct.

Join us in applauding the BMT Aerospace Belgium plant for setting a benchmark in safety that resonates across the industry. Together, we are forging a future where the well-being of our employees is at the forefront of all we do.

The significance of Bevel Gears in Aerospace

A bevel gear is a type of gear with teeth that are cut along the cone-shaped surface of the gear. Unlike spur gears, which have teeth that are cut along a cylinder's surface. This cone shape allows bevel gears to transfer motion and power between intersecting or non-parallel shafts, typically at a right angle.

The importance of bevel gears in helicopters

Bevel gears play a crucial role in the transmission systems of many machines, including helicopters. They are designed to transfer power between shafts that are not parallel, typically at a right angle. This allows for the transmission of power in machines where space is limited or where the shafts need to change direction.

In helicopters, bevel gears are commonly used in the main rotor gearbox as well as the tail rotor. The main rotor gearbox is responsible for transmitting power from the engine to the main rotor shaft, which spins the helicopter's rotor blades and generates lift. Bevel gears in the main rotor gearbox are necessary because the engine is usually mounted horizontally, while the main rotor shaft is mounted vertically. This means that the power from the engine needs to be transmitted at a right angle to drive the rotor. In other words, without bevel gears, a helicopter wouldn’t be able to fly.

Below you can see indicated in purple where the bevel gears of the main rotor gearbox are situated in a helicopter drive system. Curious to learn how a helicopter drive system works? This video explains it in detail.

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Mastering precision machining

Manufacturing bevel gears can be challenging for several reasons. Firstly, they require precise machining to ensure that the teeth mesh correctly and that the gears operate smoothly and efficiently. This precision machining requires specialized equipment and skilled operators, which can increase manufacturing costs. Additionally, bevel gears often have complex shapes, with curved teeth that are more difficult to manufacture than straight teeth. Finally, the tolerances for bevel gears are typically tighter than for other types of gears, meaning that even small errors in manufacturing can lead to significant problems in the operation of the gear system.

Despite these challenges, bevel gears are widely used in helicopters and other machines because of their ability to transmit power efficiently at right angles. By allowing power to be transmitted between shafts that are not parallel, bevel gears play a crucial role in the operation of many mechanical systems.

BMT Aerospace as your bevel gear specialist

At BMT Aerospace, we take pride in our commitment to excellence and innovation in the field of spiral bevel gear manufacturing. With a focus on precision engineering and cutting-edge technology, we continue to deliver superior solutions that meet the stringent demands of the aerospace industry. Our dedication to quality and customer satisfaction drives us to push the boundaries of what's possible, ensuring that our partners receive the highest caliber products and services. Interested to learn more? Get in touch!

Flying High: How BMT Aerospace Elevates Wing Dynamics

At BMT Aerospace, our meticulously engineered parts play a key role in optimizing aircraft performance. More specifically by influencing the dynamics of the wings. These components, including precision racks, pinions, and lever bearing assemblies, are integral to the adjustment systems of slats and flaps. They have a profound impact on the functionality of these essential wing elements.

Understanding the Significance of the Wing

The wing of an aircraft is more than just an aerodynamic shape; it is a complex system designed for optimal lift and control. The ability of an aircraft to lift off the ground and land safely is tied to the performance of its wings. Wings generate lift through the difference in air pressure between the upper and lower surfaces. This lift force is essential for overcoming gravity during take-off and providing a controlled descent during landing.

The Crucial Role of Slats and Flaps

Enter slats and flaps, the dynamic components that improve the performance of the wings. Situated at the leading and trailing edges, slats and flaps are considered 'high lift devices.' These movable surfaces significantly alter the aerodynamic characteristics of the wings, allowing the aircraft to operate effectively at varying speeds and conditions.

Take-off Dynamics

During take-off, the deployment of slats and flaps is crucial. By extending these surfaces, the wing's surface area increases, and the angle of attack is adjusted. This adjustment creates a greater lift force, enabling the aircraft to take off at lower speeds. This capability is important because it allows planes to take off in shorter distances, which makes them more flexible and safe to operate.

As the aircraft gains altitude and speed, the extended slats and flaps are gradually retracted. Here, BMT Aerospace's lever bearing assemblies and racks and pinions play a vital role in the seamless and precise retraction process, ensuring optimal aerodynamic efficiency.

Landing Dynamics

Similarly, during landing, slats and flaps play a critical role in the controlled descent of the aircraft. By extending these surfaces, the wing's lift capacity is increased, allowing for safe landings at reduced speeds. This capability is particularly essential for operations on shorter runways, enhancing overall safety and expanding the range of airports accessible to aircraft.

Conclusion

In essence, the intricate dance of slats and flaps, supported by BMT Aerospace's precision-engineered components, is integral to the symphony of flight. By optimizing the dynamics of the wings, we contribute to safer, more efficient take-offs and landings, underscoring our commitment to excellence in aviation.

What does a Tail Rotor do?

When someone hears “helicopter”, the first thing that comes to mind must be the distinctive rotor blades on top, their movement and the sound they make during arrival. Everyone knows that the blades are what makes the helicopter able to fly. But do you also know what the pivotal role of the tail rotor in a helicopter is? To understand this, we need to dive deeper into how a helicopter works.

The Flight Dynamics of a Helicopter

At the core of helicopter flight is the generation of lift by the main rotors. As these blades rotate, they propel air downward, lifting the helicopter off the ground. However, this fundamental principle introduces a challenge that demands a sophisticated solution.

Torque and Newton's Third Law

Newton's third law of motion dictates that for every action, there is an equal and opposite reaction. In the context of helicopter rotors, this law manifests as torque. As the main rotors turn, the fuselage experiences a counter-rotational force, threatening to induce uncontrolled circular motion.

Enter the tail rotor—a vertical or near-vertical set of blades positioned at the rear of the helicopter. Its primary function is to counteract the torque generated by the main rotors. By pushing the helicopter in the opposite direction of the torque, the tail rotor ensures stability during flight, preventing the aircraft from wobbling or rotating uncontrollably.

Compensating for Torque and Providing Thrust

Not only does the tail rotor counteract torque, but its strategic placement also provides additional thrust in the same direction as the main rotor. This careful balancing act contributes to the overall stability of the helicopter.

Directional Control

Beyond stability, the tail rotor serves a crucial role in directional control. The pitch angle of the tail rotor blades can be altered to facilitate controlled turns. Pilots achieve this control through anti-torque pedals located in the cockpit, allowing for precise adjustments to the helicopter's orientation.

BMT Aerospace’s contribution to smooth flights

BMT Aerospace stands as a premier manufacturer specializing in the production of bevel gears crucial for the optimal performance of helicopter rotor systems. Our portfolio of applications include prestigious helicopters, such as Sikorsky’s Black Hawk and Boeing’s Apache. Recognizing the pivotal role of bevel gears in the tail rotor assembly, BMT Aerospace employs cutting-edge engineering and precision manufacturing techniques to ensure the highest standards of quality and functionality.

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These bevel gears serve as integral components in transmitting power from the main rotor transmission to the tail rotor, effectively changing the direction of rotation at a right angle. Our commitment to precision and durability ensures that BMT Aerospace’s bevel gears contribute significantly to the smooth operation, torque distribution, and overall stability of helicopters in flight. With a focus on excellence and innovation, BMT Aerospace plays a vital role in advancing the capabilities of tail rotor systems, reinforcing the reliability and performance of helicopters worldwide.

The Crucial Role of APUs in Aircraft Operations

In the dynamic world of aviation, every component plays a pivotal role in ensuring the safety, efficiency, and reliability of aircraft. Among these essential components, the Auxiliary Power Unit (APU) stands out as a silent powerhouse for smooth aircraft operations. At BMT Aerospace, we take pride in our commitment to manufacturing cutting-edge ring gears for APUs in the aviation industry.

The Crucial Role of APUs in Aviation

An Auxiliary Power Unit is a vital part of an aircraft located in the tail section. Its role is crucial for multiple reasons:

1. Independence and Redundancy:APUs serve as an independent power source for aircraft when their main engines are not running. This independence is crucial during ground operations, providing power for systems such as air conditioning, lighting, and avionics. During flight, APUs act as a backup power source, ensuring redundancy and enhancing the overall safety of the aircraft.
2. Starting Main Engines:Before the main engines are started, APUs facilitate the initiation process. They provide the necessary power to start the aircraft's engines, playing a pivotal role in the overall ignition sequence. This capability is particularly vital in remote locations or when the aircraft is parked away from ground power sources.
3. Optimizing Fuel Efficiency:APUs contribute to fuel efficiency by allowing aircraft to operate without relying on ground power units. This independence reduces the need for external energy sources during pre-flight preparations. It also minimizes fuel consumption and enhances the overall cost-effectiveness of air travel.
4. Enhancing Passenger Comfort:BMT Aerospace's state-of-the-art ring gears for APUs ensure a comfortable and safe environment for passengers and crew. By providing power for air conditioning and other systems during ground operations, APUs ensure that passengers experience a pleasant climate while boarding, disembarking, or waiting on the tarmac.

Contributing to APU excellence

In the complex world of aviation, every part has a job to do. The Auxiliary Power Unit (APU) steps up as a silent hero, giving aircraft the power they need to work smoothly. At BMT Aerospace, we're all about delivering top-notch ring gears for APUs that airlines and operators all over the world can count on for improved safety, efficiency, and passenger comfort. As we look ahead to the future, BMT Aerospace remains at the forefront of the aviation industry, making a big impact on how planes operate and ensuring a seamless journey for passengers worldwide.

Learn more about how the Auxiliary Power Unit (APU) contributes to starting the engine of an aircraft here.

Elevating Compressor Technology: BMT Aerospace’s Breakthrough Impellers for Johnson Controls

In the dynamic realm of technological innovation, BMT Aerospace takes center stage as the developer of impellers for a new type of compressor. What makes this development extraordinary is that it made use of additive manufacturing. This technology is rapidly developing and slowly but surely offers more opportunities in more and more industries.

Additive manufacturing played a central part in the development of the impellers, as this technology was key in manufacturing the meticulously optimized thin impeller blades. These are specifically crafted to meet stringent pressure and flow requirements. Additionally, the use of Titanium addresses the corrosion resistance needed for the gas flowing through the system.

More specifically, the Electron Beam Powder Bed Melting technology was chosen to print these parts. This for multiple reasons, such as cost-effectiveness, precision in shape, no internal stresses and the general quality & strength of the resulting material.

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No climbing a mountain without challenges

It’s no secret that the journey to perfection is not without challenges. Post-printing, the impellers require a series of post-processing steps to refine the surface roughness. With years of accumulated knowledge, the BMT Aerospace team is able to fine-tune these crucial components to perform at best capacity.

While a portion of the post-printing operations is outsourced because the production volume is not yet high enough, a part takes place at BMT Aerospace. Operations directly related to the printing process initiate the production journey in-house, heat treatment and 2 surface finishing steps are outsourced and parts come back in-house for final machining operations, dimensional quality checks, and certification toward the end of the process.

One step in the marathon

Simultaneously, alongside the impellers, other work orders are in progress that include witness samples to proof the quality of additive manufacturing. These orders involve tensile test bars showcasing the material characteristics of the printed components. This data, combined with information from previous print builds, contributes to the ongoing effort to substantiate printing quality for aerospace applications.

Throughout the production of these components, BMT Aerospace adheres to a DNV-certified process. The future of these impellers, crafted by BMT Aerospace, hinges on the success of the tests JCI will conduct with the compressor. Should the tests prove successful, a new market could open up, marking a revolutionary era in compressor technology, as envisioned by the optimistic client.

BMT Aerospace sponsors CWRU Motorsports BAJA SAE team!

BMT Aerospace, Engineered Heat Treat and BMT Additive teaming up!

BMT Aerospace proudly supports the CWRU Motorsports Baja SAE team from Case Western Reserve University. As a leading manufacturer of aircraft parts, we understand the importance of precision and innovation in engineering.

Our subsidiary, Engineered Heat Treat (EHT), specializes in heat treating parts, ensuring the durability and performance of critical components such as gears for the team's gearbox. Additionally, we manufacture gears for their gearbox, cut splines for their four-wheel-drive system. Our other subsidiary, BMT Additive, is utilizing advanced 3D printing technology to produce titanium rear driveshafts.

This partnership underscores the depth of our commitment to the CWRU Motorsports team. By providing essential components and leveraging our expertise in heat treatment and additive manufacturing, we empower them to compete at the highest level. Together, we embody the spirit of collaboration and innovation, driving towards excellence in motorsport engineering.

The Baja SAE collegiate

The Baja SAE Collegiate Design Series is a competition organized by the Society of Automotive Engineers (SAE) International. It challenges students from universities worldwide to design, build, and race off-road vehicles. The series includes several events, such as Baja SAE, which focuses on off-road racing, and Baja SAE Electric, which emphasizes electric vehicles.

Teams are required to design and construct a vehicle that can withstand the rigors of off-road terrain while also meeting specific performance criteria. This includes tasks like maneuverability, suspension design, acceleration, and endurance.

Throughout the competition, teams not only race their vehicles but also present their design and manufacturing processes to a panel of judges, who evaluate their engineering decisions, cost management, and overall performance.

Participating in the Baja SAE Collegiate Design Series provides students with invaluable hands-on engineering experience, teamwork skills, and exposure to real-world automotive engineering challenges. It's a fantastic opportunity for aspiring engineers to apply classroom knowledge to practical problems and gain insights into the automotive industry.

Our team from Case Western Reserve University

The CWRU Motorsports Baja SAE team from Case Western Reserve University has achieved remarkable success, demonstrating their excellence in engineering and performance. Their accolades include a 5th Place Sales Award, a 5th Place Design Award, a 2nd Place Acceleration Award, a 4th Place Maneuverability Award, a 9th Place Endurance Award, and a 5th Place Overall Performance Award. These achievements reflect their dedication, innovation, and relentless pursuit of excellence in the competitive arena of motorsport engineering. You can find the full list of their achievements over the years on their website.

BMT Aerospace is thrilled to be working with young talent at the university, pushing the boundaries of innovation together. It makes us proud to see the all the accomplishments, as we feel that we are part of this incredible team as well.

BMT Aerospace introduces in-house Training for Employee Development

At BMT Aerospace, we understand that investing in our employees is key to long-term success. By offering robust in-house training programs, we empower our team members to grow professionally while enhancing the company’s overall performance. These training opportunities not only foster personal development but also help us maintain our competitive edge in the aerospace industry.

Project management training 2023

Strengthening Project Managers' Skills for Optimal Performance

We are thrilled to announce the launch of our project management training program, designed to enhance the skill set of our project managers. Given the important role project management plays in our business, investing in our employees' capabilities is a strategic move towards achieving our goals more efficiently.

To initiate this program, we have organized a training course that covers the project management fundamentals. The course is led by experienced trainer Mr. Didier Brackx, renowned for his expertise in project management. Mr. Brackx has generously shared valuable insights and practical tips on effective project management techniques.

The training course, organized by BMT Aerospace, welcomes all project managers within the company. It covers a broad range of topics, including project planning, risk management, communication, and leadership. The interactive and engaging nature of the course facilitates active participation, enabling participants to ask questions and share their experiences freely.

Upon completion of the course, participants will undergo an internal examination to assess their knowledge. Those who successfully pass the exam will be recognized and rewarded with a token of appreciation from the company, acknowledging their dedication and hard work.

Project Management Training 2023: Strengthening Leadership for Project Success

We’re excited to announce the successful launch of our Project Management Training Program in 2023. This initiative is designed to boost the skills of our project managers and improve the efficiency and quality of our project execution.

Why Project Management?
Project management is a critical function in the aerospace industry, and ensuring that our team has the best tools and knowledge is crucial. This year’s program was led by Didier Brackx, an experienced project management trainer renowned for his insights and hands-on approach. With over 20 years of expertise, Mr. Brackx shared valuable techniques and strategies in project planning, risk management, communication, and leadership.

Interactive Learning for Real-World Application
The program’s interactive structure allowed participants to engage with the material actively—asking questions, sharing experiences, and solving problems in real-time. Topics covered included:

• Project planning & execution
• Managing risks and uncertainties
• Effective communication and leadership in teams
• Problem-solving and decision-making in complex environments

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Internal Assessment and Recognition: A Step Towards Excellence

To ensure participants gained a solid understanding, the program concluded with an internal exam. Successful candidates who demonstrated comprehensive project management skills were awarded a certificate of completion and a token of appreciation from BMT Aerospace, recognizing their hard work and commitment.

Graduates of the Project Management Training 2023:

• Koen Roggen
• Dieter Moens
• Ewald Goossens
• Denis De Clercq
• Jurgen Versluys
• Olivier Vanden Borre
• Frederik Deprince
• Jan Peirs
• Charlotte Sticker
• Simon Depoortere
• Danut Oprea
• Ionut Bocanet
• Karan Ghuman
• Kyle Ashworth
• Marinela Ginga

CEO Benoit Reynders expressed his pride in this initiative, noting that these graduates are now better equipped to handle the complexities of aerospace projects with increased efficiency and confidence.

The Value of In-House Training: Driving Continuous Improvement

At BMT Aerospace, we believe that continuous learning is the foundation of success. By investing in our employees’ development, we ensure that our projects are executed on time, within budget, and to the satisfaction of our clients. The Project Management Training Program is just one example of how we’re fostering excellence and driving our company forward.

As we continue to expand our training offerings, we remain committed to nurturing a culture of growth, innovation, and professionalism within our team. We are proud of the positive impact this program will have on our business, helping us achieve operational excellence and client satisfaction.

Investing in the Future of Aerospace Excellence

Through in-house training, BMT Aerospace is not only investing in the personal growth of our employees but also ensuring the continued success of our company. Our dedication to training and development is a core part of our mission to lead in the aerospace industry, and we look forward to the continued professional growth of our team.

Early Adoption Industry 4.0 – BMT Aerospace’s Makino 1 and Okuma

Industry 4.0 represents the fourth industrial revolution, which is characterized by the integration of advanced technologies such as the Internet of Things (IoT), big data analytics, artificial intelligence (AI), and robotics, among others, into manufacturing processes.

Today, there are already many automated processes within our company, think about milling, deburring, heat treatment, copper plating, CMM measurement, and so on. For some of these processes, we have our machines called the Makino and the Okuma.

The Makino 1 we have had since 2015, the Okuma since 2020. Today, both machines are fully automated with a robotic arm and a robotic tower.

The Makino is a grinder that does the gearing on racks. This process happens before heat treatment. The Okuma does the roughing and pre-milling of the racks.

What advantages does the automation give?

Previously, operators had to take the pieces in and out of the machines themselves. Automation allows us to use our operators for other processes, which makes the work more challenging for them. They can focus more on complex work. In addition, we can increase our capacity; with automation, everything runs more smoothly and we can also continue working at weekends. This gives benefits on many levels.

The Makino in itself is a technically advanced machine that delivers quality products, we can grind and drill in 1 clamping. In addition to the robotic arm, there is also a robotic tower, which provides vertical storage that utilizes the height of the factory.

The integration of our robotics into manufacturing processes lead to increased efficiency, reduced costs, and improved quality. By leveraging Industry 4.0 technologies, we can achieve real-time monitoring of production processes, predictive maintenance, and optimized supply chain management. This can lead to faster response times to changing customer demands, reduced downtime, and increased throughput.

BMT Aerospace contributes to 5000th delivery of iconic Black Hawk

Last month, the 5000th Black Hawk helicopter was delivered to the US Army by Sikorsky. Since BMT Aerospace has been delivering main rotor and tail rotor gears for this iconic helicopter since 2009, this means that we also contributed to the delivery of the 5000th Black Hawk. Something we are very proud of!

Forty years ago, the first Black Hawk was delivered and has since been employed by over 30 countries. The U.S. Army's intention to continue using the Black Hawk in frontline operations for another 40 years is a testament to its reliability.

Our contribution for the Black Hawk

BMT Aerospace is honored to have been selected as the supplier for complex input module bevel gearing, main rotor transmission gears, and flight safety tail rotor bevel gears used on the Black Hawk Helicopter.

Due to part complexity, Sikorsky had experienced difficulty obtaining hardware from their existing supply chain. These parts require maintaining close, consistent tolerances through heat treatment and finish machining to meet final part geometry and case depth properties. BMT Aerospace was chosen as a trial source in 2009 for these Black Hawk gears and quickly became the primary source of supply for production hardware.

Below you can see an example of how our parts are implemented in helicopters.

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About the Black Hawk

Sikorsky, now a subsidiary of Lockheed Martin, developed the Black Hawk in the 1970s. It has since become a widely used medium-lift utility helicopter for both military and civilian operators around the world.

The Black Hawk is renowned for its versatility, as it can be deployed in a variety of missions such as troop transport, medical evacuation, search and rescue, and special operations. Subsequent variants have been released over the years with improved avionics, engines and rotor systems; the most recent being the UH-60M model.

This helicopter is known for its ruggedness, reliability and low maintenance requirements which make it suitable for use in different environments and conditions.

BMT Aerospace Celebrates More Than 50 Years’ Partnership with the U.S. Aerospace Industry

Flanders’ Minister-President Jan Jambon visits company that builds mission-critical components for the F135 advanced fighter engine of the F-35 Lightning II – Joint Strike Fighter.

Detroit, MI/Oostkamp, Belgium, January 30, 2023 – BMT Aerospace, specialized in making high precision products and complex assemblies for turbine engines and mission-critical aircraft components, celebrated more than 50 years of successful partnership with the U.S. Aerospace Industry at a ceremony in Belgium in the presence of Flanders’ Minister-President Jan Jambon today.

BMT Aerospace CEO Benoit Reynders said: “We are very proud to be part of Pratt & Whitney’s F135 advanced fighter engine program powering all 3 variants of the F-35 Lightning II – Joint Strike Fighter (JSF). BMT has been a supplier to Pratt &Whitney for over 50 years now. Our participation in the global F-35 JSF Program is a confirmation of how our expertise, management, and know-how ‘Made in Flanders’ is being appreciated by Air Forces all over the world.”

Minister-President Jan Jambon of Flanders, Belgium’s northern region, commented:

"The aerospace industry plays an enormously important role for the Flemish export economy. Flanders accounts for 2% of world trade by land, sea and air. It is therefore no coincidence that BMT Aerospace's headquarters are in Flanders. For more than 50 years, BMT has been designing, innovating and building components for commercial, military and space programs. Flanders, together with its strategic partners is strongly committed to innovating in its export economy."

BMT Aerospace, with manufacturing operations in the EU and in the USA is a partnering supplier to Pratt & Whitney and currently produces Engine and Accessory Gearbox components in support of the following P&W programs:

F135 Engine -> F-35 Joint Strike Fighter

PW1000 Engine -> A320 NEO / A220 / Embraer E-Series commercial airliners

F100 Engine -> F-15 / F-16 Fighter Jets

JT3/TF33 Engine -> B-52 Bomber / KC-135 Tanker

A detailed document outlining the Integrated Country Strategy for Belgium with the U.S. Office of Defense Cooperation can be found here.

BMT Aerospace equally provides mission-critical components to the Sikorsky UH-60 Blackhawk and CH-53E Super Stallion and the latest CH-53K King Stallion helicopter series as well as the Lockheed-Martin C-130 Hercules military transporter. BMT Aerospace is active in almost every major aerospace platform, including Airbus’ A320, A330, A350 and A380 aircraft, and manufacturing gears and gearboxes for jet engine manufacturers Rolls Royce, General Electric, Honeywell, Safran and UTC.

No starting an engine without BMT Aerospace!

If you ever traveled by plane, you probably recognize the excitement you feel while awaiting take-off. In those moments, did you ever wonder how aircraft engines are started? It is a complex process involving four aircraft systems (APU, starter, AGB, PTO). Did you know that BMT Aerospace is present in all these crucial parts that are needed to start an aircraft engine?

In short, it’s impossible to start an engine without BMT Aerospace! Curious how this process takes place? Learn more about it below.

How does an aircraft start?

The following parts are crucial in the activation process of an aircraft.

1. Auxiliary Power Unit (APU)

The Auxiliary Power Unit is an independent small turbine generating electrical and pneumatic power for a variety of aircraft systems. It is typically located in the tail section of the aircraft and provides power for air conditioning, cabin pressurization, and other auxiliary systems.

BMT Aerospace manufactures ring gears for the APU in the tail of the plane.

2. Starter

The starter is connected to the Accessory Gearbox (AGB) of the main engines. When activated, it provides the necessary torque to spin the engine up to operating speed.

BMT Aerospace manufactures spur gears for the starter for aircraft starters.

3. Accessory gearbox (AGB)

The AGB is an engine module that allows all subsystems of the aircraft (electrical, pressured air, pressured oil system, etc..) to operate thanks to the power extracted from the main engine (unique power plant on board). The AGB will empower all accessories via a complex drivetrain of spurs, bevels and gears. The AGB is connected to the Main engine shaft via the PTO.

BMT Aerospace manufactures high-end components of accessory gearboxes (housings and gears).

4. Power take-off shaft (PTO)

The PTO is a shaft put in motion from the main engine shaft via the internal gearbox (IGB) and driving the motion up to the AGB.

BMT Aerospace can manufacture internal gearbox components, as well as shafts of the PTO’s shafts.

The process

These parts of the aircraft are in co-relation with each other and are crucial to start the aircraft engines. The process goes as follows:

The APU is an autonomous source of power and will generate compressed air and electricity to the starter. On its turn, the starter will set the AGB in motion. The accessory gearbox will then drive the PTO and this will activate the main engine shaft. This will eventually activate the compressor. When the compressor has heated the air enough, fuel is injected and the engine can start.

BMT Aerospace is a world-class leader in manufacturing complex parts for aircrafts. We manufacture more than gears that play a role in the start-up of the engines. Discover all our products here.

BMT Additive is ready for ProGRAM JIP Phase III

3D printing is rapidly advancing and is introduced in more industries every day. Introducing additive manufacturing in complex industries like the aerospace industry, energy, oil & gas and maritime industry is not an easy task. Some parts are complex to make and have extreme quality demands because of the important role of the part in the application.

That is why BMT Additive, a part of BMT Aerospace that focuses on additive manufacturing, joined ProGRAM JIP; a joint industry program of the energy, oil & gas, maritime and aerospace industry to standardize additive manufacturing processes in these industries. The project is an initiative of DNV.

Accomplishments

JIP ProGRAM Phase I

So far, ProGRAM JIP successfully completed two phases. Phase one resulted in the new additive manufacturing standard DNV-ST-B203 using laser powder bed fusion technology.

DNV-ST-B203 is a standard published by Det Norske Veritas (DNV), an international classification society. It outlines the requirements for the design, construction, and operation of offshore pipelines. This standard is used to ensure the safety and reliability of offshore pipeline systems, as well as to protect the environment from potential risks associated with such systems.

JIP ProGRAM Phase II

JIP Phase II had started in late 2020 with a wider attendance from various industries and lasted 2 years. The result was an updated DNV-ST-B203 standard with the addition of Electron Beam Powder Bed Fusion (E-PBF), Wire Arc Additive Manufacturing (WAAM), Directed Energy Deposition (DED) and Metal Binder Jet Fusion (MBJF). Extensive work has been performed with case studies for each technology to support the new standard and make it more usable for the industry. The new B203 standard was released in October 2022.BMT Additive joined the project in this phase and contributed by expanding the standard with E-PBF and a case study with a pump impeller for Equinor.

Ready for phase III

Phase III of the JIP program will be launched in October 2023. A wider range of OEMs will attend the project in this phase. The aim of phase III is to extend the DNV-ST-B203 standard with the following aspects:

• Design for AM
• Part Family Qualification
• Repair/Remanufacturing with AM
• Post-Processing (surface finishing, heat treatment)
• Environmental footprint and sustainability

The project includes many part manufacturers that provides the main AM technologies; L-PBF (Laser Powder Bed Fusion), E-PBF (Electron Beam Freeform Fabrication), WAAM (Wire Arc Additive Manufacturing) and DED (Directed Energy Deposition). The Work packages will be supported by case studies with these AM technologies.

ProGRAM JIP Phase III is set to be completed in 2024. We are looking forward to continuing collaboration with valued industry partners and supporting accelerated adoption of Additive Manufacturing.

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BMT Aerospace Romania renews Nadcap certificates

Recently, BMT Aerospace Romania's Nadcap certificates for several processes were renewed.

What is Nadcap?

Nadcap, short for "the National Aerospace and Defense Contractors Accreditation Program", is a global cooperative accreditation program for aerospace engineering, defense and related industries. Since the beginning of the program, Nadcap has evolved into an essential selection criterion for programs in the aerospace industry. It’s also an important asset in the relationship between suppliers and customers in the industry.

Renewal for BMT Aerospace Romania

BMT Aerospace Romania recently renewed its certificates for the following manufacturing processes:

– Chemical processing
– Heat treatment
– Machining and assembly of several parts
– Non-destructive testing
– Surface enhancing

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Discover all the BMT Aerospace certificates and accreditations here.

BMT Aerospace Chooses DNV for AM Process Qualification for Energy, Oil & Gas and Maritime Industries

BMT Aerospace Chooses DNV for AM Process Qualification for Energy, Oil & Gas and Maritime Industries

Additive Manufacturing is making its way into various industries. Not just for prototyping, but also as a viable technique for serial production. Its benefits in design freedom, lead time reduction and supply chain benefits are clear, yet lack of relevant standards is limiting mass adoption. This is the main reason for DNV to create the Additive Manufacturing standards DNVGL-ST-B203 for the Energy and Maritime industries. ProGRAM JIP Phase II has seen Electron Beam Powder Bed Fusion Technology successfully added to the standard.

Following JIP Phase II, BMT Aerospace has chosen DNV for Facility Certification and Part Production Specification (PPS) for EB-PBF process, according to the DNV service specification DNVGL-ST-0568.

Certifying an AM facility to a globally recognized DNV’s AM ‘Facility Certification’ standard provides assurance that the qualified facility meets the rigorous criteria, confirmed by qualified AM experts. AM process qualfication provides peace-of-mind to end user customers with a strong emphasis on reliability and capability verification of AM manufacturers. That way, certification holds more value to customers, regulators or others who are in need of certified AM parts.

“DNV facility certification and part family qualfication is very important for BMT aerospace to support our growth target in Energy and Oil & Gas application area. We see the great potential of AM in these industries, and clearly these certifications will provide us to create trust with our end user customers with a right level of assurance and help them to integrate our services in their just-in-time manufacturing supply chain. With this certification we are also looking forward to providing our customers’ necessary confidence in the quality and repeatability of our AM process.” said Ewald Goossens, Innovations & New Technologies Manager at BMT Aerospace.

Dr. Sastry Kandukuri, Global AM Practice Lead and Senior Principal Materials Specialist at DNV’s Energy Systems Business Unit in Norway, said the following:

“DNV’s Facility Certification is based on our extensive experience and help the manufacturers with necessary awareness about quality requirements of industry recognized standards, identify and mitigate manufacturing risks, and serves as a basis for closing and managing the gaps. Our current customers and potential clients are increasingly interested in the benchmarking of the AM facilities they wanted to use in future projects. We are very happy to see that BMT Aerospace have chosen to work with us and we are looking forward to add value through our competence, integrity and independence”

The certification project is aimed to be completed by the end of this year.

EHT is joining the BMT Aerospace family!

We are proud to announce that Engineered Heat Treat, LLC (EHT) will join the BMT Aerospace division. EHT is a successful business which executes heat treatment for several industries (e.g. Aerospace, Agriculture, Automotive, and military).

EHT is a family business to its core and origins back to 1959. Brothers, Ron and Greg Pilibosian, are currently leading the company and will continue to do so with a direct reporting line to Benoit Reynders.

A logical step

EHT is already a well-known supplier to BMT Aerospace US and has been for many years. Due to this new cooperation, we will be able to perform our heat treatment in-house. This means that BMT Aerospace US will have a vertically integrated production process just like BMT Aerospace in Belgium and Romania. A big added value for us and our customers!

This acquisition brings together BMT Aerospace’s high-end gear manufacturing capabilities in Fraser, Michigan, with one of the leading heat treatment providers in the Detroit area. For BMT Aerospace, this is an important step into the future and supports the strategic transformation we are going through. We believe this acquisition provides a great opportunity to accelerate the value we bring to our customers.

Fully vertically integrated

A big part of this deal is accelerating BMT Aerospace’s operational performance through supply chain integration. Operational excellence has always been our strategic mindset. Integrating EHT’s capabilities with BMT Aerospace’s services will allow us to manage lead time and drastically improve response time.

Based on our experience with BMT Aerospace’s vertically integrated plants in Belgium and Romania, we strongly believe that supply chain integration is key to operational and financial independence.

In addition, this transaction advances BMT Aerospace’s plans to grow as a consolidated supplier and accelerate our global strategy to become a ‘single-source’ partner to our customers. Vertical integration provides the insurance against supply chain disruptions and improves flexibility.

We’re excited to welcome our new colleagues in the BMT Group and the BMT Aerospace division in particular!

BMT Aerospace helps standardize Additive Manufacturing in multiple industries

In 2018, a consortium of twenty-three companies, managed by DNV and Berenschot, started the ProGRAM JIP project.

The goal of this project was to produce a guideline with the necessary requirements to introduce components made by Additive Manufacturing into the oil, gas and maritime industry. Together with them and the other partners in the energy, oil, gas and maritime industries, we have set the goal of standardization and adaptation of Additive Manufacturing.

Our main contribution to ProGRAM JIP Phase II was the expansion of the existing DNV Additive Manufacturing process guideline “DNV-ST-B203” by the Electron Beam Powder Bed Fusion process (a process where an electron beam is used to scan a powder bed).

As an end result, the guideline is now successfully extended by EB-PBF, WAAM, DED and MBJ processes. The new version will be released by DNV in 2022. Hopefully, this new version will further enable industrialization of Additive Manufacturing.

We are proud to announce that BMT Aerospace will join JIP ProGRAM Phase III and continue the work where Phase II left off. The project will kick off at the end of this month, where we will work to continue proving the value of AM for the industry with all the valuable partners.

Want to know more about the first two phases of the project? Read the full article starting from page 137.

BMT Aerospace has extended its title as Factory of the future!

BMT Aerospace was able to extend its previously won title.

The Factories of the Future Awards are an initiative of technology federation Agoria and Sirris, the collective center of the Belgian technological industry. This in collaboration with Fevia (food), Fedustria (textiles, wood and furniture), essenscia (chemistry and life sciences), Centexbel (textile technology), Catalisti (chemistry and plastics), Wood.be (wood and furniture), Flanders’ FOOD (agri-food) and Digital Wallonia.

𝐒𝐞𝐚𝐬𝐨𝐧’𝐬 𝐠𝐫𝐞𝐞𝐭𝐢𝐧𝐠𝐬!

All of us here at BMT Aerospace want to wish you Happy Holidays and a Happy New Year.

Time to reconnect and recharge!

BMT Aerospace received ZEISS AWARD #measuringhero

BMT Aerospace is currently working on a CMM project consisting out of a ZEISS ACCURA II with a ZEISS VAST-XTR probe, fully integrated in an automated cell with conveyors, a vertical lift shuttle system and a loading and unloading station.

With this project, BMT Aerospace was able to decrease the total measuring time per component drastically to half of the original time, to reduce administration work significantly and to lower the reject rate by 50-80 % over the last two years. With his amazing contribution, Peter Praet has inspired our jury and has won their votes.

Source: https://www.zeiss.be/metrologie/nl/campagnes/measuringhero-award/measuringhero-winners.html

Product Innovation and Development

The integrator

Where two centers of excellence meet

Factories of the Future: 12 cases in practice

How can manufacturing industry be armed against future challenges?

How do other companies deal with this and who is taking the lead in Belgium?

Discover which gearing the 12 ‘Factory of the Future’- winners of 2019 are using to embrace the future:

download the inspiration book ‘Factories of the Future: 12 cases in practice’

Ewald Goossens, Business Unit Manager of BMT Additive, will be one of the speakers during Industry Barcelona 2019!

https://www.linkedin.com/posts/3dnatives_3dprinting-industryarena19-activity-6597059942484713472-gbwL

Ewald Goossens, Business Unit Manager of BMT Additive, will be one of the speakers during Industry Barcelona 2019!

More information: http://www.industry.website/en/agenda/-/agenda-actividades/speakers/Ewald-Goossens-/40139

BMT Additive will be present at the 9th Aviation Forum in Munich, November 5th- 6th.

Let’s meet!

Contact Mr. Geert De Donder to set up a meeting => Geert.DeDonder@bmtaerospace.com

Carpenter Technology and BMT Aerospace combine expertise in redesign and production of additively manufactured aerospace component.

Factory of the Future roadshow lands at BMT Aerospace International

On 7 May 2019, BMT Aerospace International opened its doors for the Factory of the Future Roadshow. The event was an ideal opportunity for visitors to network, to see how Factory of the Future winner BMT Aerospace operates, and to test their own challenges against BMT’s experience.

BMT Aerospace International received the Factory of the Future Award on 6 February 2019. With this award BMT Aerospace emphasizes its ambition to be an agile and future-proof company that delivers products with a higher added value. BMT Aerospace International will retain the Factory of the Future label for three years.

BMT Aerospace received 24 guests for the roadshow in Oostkamp. The visitors were able to follow a tour around the company and learn more about BMT Aerospace’s achievements so far in the transformation trajectories from Sirris and Agoria’s Made Different Action Plan (more specifically: the trajectories ‘World Class Manufacturing Technologies’, ‘Digital Factory’ and ‘Production Network’).

“We had a very successful Factory of the Future Roadshow,” says Koen Devolder, Site General Manager of BMT Aerospace International. “We had the opportunity to network and exchange ideas with like-minded industrial professionals. For BMT Aerospace, it’s an honor to serve as an example of how a company can follow the Factory of the Future trajectory.”

BMT Aerospace will present its experiences for the second time on 6 June 2019, in the framework of Agoria’s Made Different program.

About BMT Aerospace

BMT Aerospace International supplies high-tech precision components for the aviation sector. The company operates in three locations: USA, Romania and Belgium. The Belgian branch is located in Oostkamp, employs around 120 people and has been a leading manufacturer of gears, transmission and actuation systems for the drive mechanism of the slats (attack wing) and flaps for various commercial aircraft programs for more than 25 years worldwide.

Paris Airshow 2019

It will be a joint exhibition together with BMT Additive, a subsidiary of BMT Aerospace that is specialized in 3D metal printing.

We are looking forward to welcome you at our booth – booth number F32, Hall 2B – Belgian Pavilion.

Our team will be ready to give you an overview of our production activities and entire range of products for the Commercial Aircraft, Business Jets, Regional Aircraft, Military Aircraft, Unmanned Aircraft and Rotorcraft.

BMT Aerospace will be present at the Paris Air Show 2019!

BMT Aerospace receives Nadcap accreditation for measurement and inspection

BMT Aerospace International has received Nadcap accreditation for Measurement and Inspection. The company therefor successfully passed a Nadcap audit on its Coordinate Measuring Machines (CMM). Thanks to this recognition from Nadcap, BMT Aerospace International confirms its position as a trusted manufacturer of high-precision components for the aerospace industry.

The National Aerospace and Defence Contractors Accreditation Program (Nadcap) brings together prime contractors, suppliers and government representatives to achieve a standardized, streamlined approach to quality assurance, auditing and accreditation throughout the supply chain.

The Nadcap Measurement and Inspection (M&I) certification was introduced to ensure that quality is measured across the industry consistently. Nadcap’s M&I certificate takes a wider and more in depth approach than most current audit programs, looking at everything from employee skills to measurement process validation practices, maintenance and measurement environment.

First Nadcap M&I certification in Belgium

“We are glad to receive this Nadcap accreditation, because it is a recognition for both our technological capabilities and our people,” said Peter Praet, Quality Assurance Manager at BMT Aerospace International. “The fact that BMT Aerospace International is the first Belgian company to receive this certification makes it extra special.”

In order to receive the accreditation, BMT Aerospace International took part in an extensive audit of its measurement and inspection processes. Aided by the company’s experience with previous Nadcap certifications, BMT passed the M&I audit in February 2019 with flying colors.

Critical processes

M&I processes are used throughout manufacturing to verify whether products meet specification. Failure to accurately measure can lead to performance degradation, sub-optimal products, manufacturing and assembly problems, increased cost and lead-time, reduced life, and part failure. Today, only a few of these processes are audited at a detailed industry-wide level, which means that M&I basics are being missed in current audit programs and there is a high risk of product impact. With its M&I program, Nadcap meets the need for a quality assurance program according to the aerospace industry’s high standards. This way, an effective measurement and inspection process for product acceptance is guaranteed.

BMT Aerospace wins ‘Factory of the Future’ award!

BMT Aerospace International may call itself a Factory of the Future for the next three years. The company received this award during the fifth edition of the Factory of the Future Awards in Kortrijk. With this award BMT Aerospace emphasizes its ambition to be an agile and future-proof company that delivers products with a higher added value.

Since 2015, technology federation Agoria and the collective center for the technology industry Sirris have been presenting the annual Factory of the Future Awards. Factories of the Future invest in digitization, in smart processes and products and in world-class production, but they also deal with energy and materials in a well-considered way and pay attention to the involvement, creativity and autonomy of their employees.

“This award is an acknowledgement for the passion of our people,” says Koen Devolder, Site General Manager of BMT Aerospace International. “As early as 2016, we expressed our ambition to become a Factory of the Future by setting up an integrated optimization strategy. This has clearly paid off. In our optimization plan, we have not only focused on technology and digitization, but also on partnerships with other companies, our employees and on ecology.”

Seven crucial transformations

To become a Factory of the Future, BMT Aerospace International needed to complete seven transformation trajectories.

• World Class Manufacturing Technologies: deploying state-of-the-art production devices
• End-to-end Engineering: product development and corresponding services depending on the complete value chain, by means of virtual models and simulations
• Digital Factory: digitization of operational processes, connected with the internet
• Human Centered Production: employee involvement in the future development of their company
• Production Network: the organization is embedded in an optimal eco-system of suppliers and partners
• Eco Production: a sustainable production system considering each phase of a product’s life cycle, from acquiring the materials, production and usage, to disposing of the waste. Production systems are also able to close the materials cycle and energy consumption is drastically reduced.
• Smart Production Systems: to be able to respond to rapidly changing market demand

These transformation processes resulted in many concrete projects. The company is particularly proud of:

• Cooperation with machine constructors for the development of special metallurgical machines (World Class Manufacturing Technologies)
• Development of open communication, training and small self-managing teams (Human Centered Production)
• Co-design of parts together with the customer and rapid prototyping for a faster time to market (End-to-end Engineering)

Continuous improvement

“For us, the Factory of the Future Award is a catalyst for an improvement process that never stops,” says Koen Devolder. “That’s why we have already laid out our roadmap for 2020 and beyond. Only in this way we can cope with an ever-changing market.”

The Factory of the Future Awards were presented on 6 February 2019. BMT Aerospace International will retain the Factory of the Future label for three years. The company will present its innovative approach at the Factory of the Future Roadshow on Tuesday 7 May 2019.

About BMT Aerospace

BMT Aerospace International supplies high-tech precision components for the aviation sector. The company operates in three locations: USA, Romania and Belgium. The Belgian branch is located in Oostkamp, employs around 120 people and has been a leading manufacturer of gears, transmission and actuation systems for the drive mechanism of the slats (attack wing) and flaps for various commercial aircraft programs for more than 25 years worldwide.

Nadcap accreditation for Materials Testing

BMT Aerospace and Digital Transformation

BMT Additive

BMT Aerospace International N.V. acquired all of the shares of the previous Joint Venture AMT Titastar. The company name has changed to BMT Additive N.V. as from December 28th, 2017.
BMT Additive focuses on metal 3D printing for aerospace and non-aerospace activities incl. design and post processing.

For all your enquiries please contact sales@bmtaerospace.com.

New BMT Aerospace facility in Iasi Romania

New BMT Aerospace facility in Iasi Romania operational since August 2017.
Fully integrated company:
– Machining gears and housings
– Heat treatment
– Platings
– Surface Enhancements

Golden award from Liebherr Aerospace

For the second time in three years, BMT Aerospace Romania has won the Golden award from Liebherr-Aerospace Lindenberg for the outstanding performance and service run by our factory in Iasi during 2015.
100% on time deliveries, 0 quality claims and 38 ppm (target 1.000) were the outstanding numbers of BMT Aerospace Romania throughout the measured period.
The award was recognized at the 2016 Annual Supplier’s Conference held at Friedrichshafen, Germany on September 21, 2016.
BMT Aerospace Romania is very appreciative of the special award and all the support received from Liebherr-Aerospace Lindenberg to achieve this result.

New arrival: Kapp Gear Grinder

With the delivery of the extended capacity KAPP VX59, BMT Aerospace has the ability to produce the latest designed engine gearing up to 800mm in diameter and a length of 1.2 meters using the highest quality machines available in industry today.

BMT Aerospace continues to invest

BMT Aerospace continues to invest for the future and has purchased a new automated hobbing machine.