For many years the Gardena, California facility of Ducommun AeroStructures has been known for innovation and expertise in metal forming. We have evolved into a versatile manufacturer with specialized services including stretch forming, thermal forming, assembly, chem milling, NC machining and processing. Our unique capabilities enable us to offer our customers several manufacturing processes at a competitive price from one supplier. This "turn-key" capability provides Ducommun AeroStructures with a competitive advantage second to none in the aerospace markets.

What really sets our Gardena facility apart, however, is the scale of our manufacturing operations. For example, our massive high-speed NC routers, the Torres mill and Henri Liné machine, are calibrated and driven with laser thermal compensation systems. These large high-speed machines allow us to NC rout and drill very large structural parts, giving design engineers the freedom to do in one skin what would have taken four or five skins.

In terms of overall capability - this facility operates the largest stretch press in the world and the largest gantry mills, demonstrating its capabilities with work on the Space Shuttle. Ducommun AeroStructures stretch-formed a large, heavy extrusion 30' long with an up to 34" cross-section into a radius on a machine that was designed internally. With our sophisticated equipment, both sides were cut simultaneously, reducing weight from 1800 pounds to 250 pounds - all without any warpage.

Tooling
Gardena's experience in tool fabrication covers all facets of the trade. Our capabilities include computer-aided design (CAD) of simple to complex jigs, fixtures and dies. Our Gardena facility was a pioneer in the development of soft tooling, utilizing layers of fiberglass and synthetic resins. We have the ability to achieve the contour and configuration of a component either from a customer furnished master pattern or computer generated loft data (CATIA). Ducommun AeroStructures is known throughout the industry for producing some of the largest ceramic and fiberglass dies. Some of these are in excess of thirty feet long and twelve feet wide. The success of any production program depends on the quality of the tooling. Our engineering expertise and versatility allow us to successfully transform extremely complex tasks into reality.

Engineering in our Gardena facility employs a modern CAD/CAM system that includes an NCL work station, a Gerber Autograph controlled by an HP 1000 computer and two HP plotters with Kennedy 9000 magnetic tape drive for mechanical design and drafting tasks. This system uses IGES (International Graphics Exchange Specification) and has APT (Automated Program Tools) capability. Loft data, contour data, spline and mesh surfaces, or ABC Data Points of XYZ, IJK points are expeditiously converted to graphics.

Stretch Forming
Stretch Forming is a process of elongating aluminum sheet and extrusions into complex structural configurations using various shape dies. Ducommun AeroStructures possesses some of the largest and most unique stretch forming presses in the United States at Gardena.

In 1951, Gardena began stretch forming sheet metal components for major aircraft companies. Along with the forming services, this facility began developing some unique approaches for both hydro and stretch forming to solve specific problems. These "unique approaches" led to the development of some rather extraordinary stretch forming machines. A typical example is one Ducommun AeroStructures press that can form sheet metal components up to .280 inches thick, 100 inches in width and 30 feet long, as well as 30 foot extrusions.

From our 1100-ton Sheridan Gray and 3200-ton hydro press to our smaller ERCO and Hufford presses, we possess the versatile capability to meet the most exacting requirements.

Our personnel are trained to handle all types of alloys, including polished materials, assuring you of the highest quality products.

Thermal Forming
Thermal Forming is a metal forming process conducted at high temperatures for the production of close tolerance titanium components. Equipment in Gardena is capable of forming large components in excess of 20 feet in length.

Titanium alloys (i.e. Ti-6AL-4V) are the popular choice for aeronautical services. Their high-strength to low-weight ratio and comparatively high yield strengths are the basis for their use as an aircraft material in either sheet or extrusion shapes. However, the high yield strengths and low modulus of titanium alloys make them difficult to form at room temperature.

When precisely controlled, elevated temperatures are employed along with specifically designed tooling, dies, and the appropriate forming press; warpage and springback problems are greatly minimized. Also, costly pre-forming, secondary sizing, hand straightening and extensive machining to achieve the final contour are usually unnecessary.

In 1970, the Gardena facility became a pioneer in the development of the vacuum box for forming large titanium plates up to 3 inches thick. The parts are removed from the vacuum box with clean and smooth surfaces. The contoured shape is produced by a combination of heat, (usually 1150° F to 1400° F) and vacuum pressure. The compound contours can be so exacting that additional surface machining is eliminated.

Machining
Gardena offers a total "turnkey" approach to the production of your components. For example, you provide us with a design or other engineering data (i.e. loft data), and we will machine or manufacture parts to your specifications and quality standards. This includes design and fabrication of tools, versatile manufacturing methods and subsequent processing required to provide a quality end product.

The production facilities at Gardena have been specifically constructed for high volume machining of aerospace components. For example, our equipment consists of three Shin Nippon Koki (SNK) 5-axis gantries, each with three spindles, mounted on 12 foot wide beds. Other CNC mills and profilers, some designed and built by Ducommun AeroStructures, were selected for their capability to machine large structures and complex contours at production rates.

In keeping pace with the ever-changing world of engineering, our Gardena facility uses state-of-the-art CAD/CAM equipment to ensure accuracy and completeness of design for tools and components used on today's aircraft. The CAD/CAM department is equipped with six RS6000 IBM computers running CATIA and Unigraphics software for both design and NC programming. Vericut and Optipath software are used to enhance the NC programming capabilities, along with two seats of Solid Works for mechanical design in support of tooling and planning. The department is staffed with experts in 3- to 6-axis programming, surface and solid design, and analysis.