Aerospace Manufacturing Engineering Course

Lesson 1 • Engineering Drawing and Specifications

Covers interpretation of technical drawings, tolerances, and model-based definitions. Connects drawing literacy to accurate part fabrication and inspection.

Lesson 2 • Manufacturing Process Families

Surveys subtractive, additive, forming, and joining process categories at a conceptual level. Establishes a mental framework for deeper process study in subsequent chapters.

Lesson 3 • Aerospace Materials Fundamentals

Introduces metallic and non-metallic material classes used in airframes and propulsion. Builds the material knowledge required for process selection in later chapters.

Lesson 4 • Aerospace Industry Overview

Maps the aerospace manufacturing ecosystem, including commercial, defence, and space segments. Provides context for understanding downstream process and quality requirements.

Lesson 1 • Resin Transfer and Infusion Moulding

Covers liquid composite moulding methods used for complex geometry and high-volume parts. Distinguishes process variants by tooling, resin flow, and quality outcomes.

Lesson 2 • Material Testing and Characterisation

Introduces mechanical testing, non-destructive evaluation, and microstructural analysis for processed materials. Validates that processing meets design allowables before part qualification.

Lesson 3 • Composite Layup and Cure Processes

Teaches hand layup, automated fibre placement, and autoclave cure cycles for carbon fibre structures. Connects cure parameters to void content and structural performance.

Lesson 4 • Aluminium Alloy Fabrication Techniques

Covers rolling, extrusion, and heat treatment of aluminium alloys for airframe structures. Links process parameters to resulting mechanical properties.

Lesson 1 • Cutting Tool Selection and Management

Covers tool geometry, coatings, and grade selection for titanium, aluminium, and composite cutting. Reduces tool failure and surface damage through informed selection.

Lesson 2 • Machining Parameter Optimisation

Applies cutting speed, feed, and depth-of-cut relationships to achieve surface finish and dimensional targets. Uses design-of-experiment approaches to optimise parameters systematically.

Lesson 3 • CNC Machine Tool Fundamentals

Explains machine axes, spindle systems, and control architecture for milling and turning centres. Provides the mechanical foundation for programming and setup tasks.

Lesson 4 • Thin-Wall and Complex Geometry Machining

Addresses chatter, deflection, and fixturing challenges specific to aerospace structural components. Applies advanced toolpath strategies to maintain tolerance on difficult features.

Lesson 1 • Mechanical Fastening Systems

Examines aerospace fastener types, installation torque, and interference-fit techniques for metallic structures. Connects fastener selection to fatigue life and structural integrity.

Lesson 2 • Assembly Tooling and Jig Design

Explains the design of assembly fixtures, drill jigs, and coordinate measurement setups for large structures. Ensures dimensional accuracy and repeatability across production builds.

Lesson 3 • Riveting and Sheet Metal Assembly

Teaches solid and blind riveting processes used in fuselage and control surface assembly. Addresses hole preparation, rivet set selection, and driven-head inspection.

Lesson 4 • Fusion and Solid-State Welding

Covers TIG, electron beam, and friction stir welding processes for aerospace metallic joints. Evaluates weld quality through process parameters and non-destructive testing.

Lesson 1 • Nonconformance and Disposition Management

Addresses material review board processes, use-as-is dispositions, and rework documentation. Ensures nonconforming material is controlled and root cause is addressed systematically.

Lesson 2 • Non-Destructive Testing Methods

Teaches ultrasonic, radiographic, eddy current, and dye penetrant inspection for internal and surface flaws. Selects NDT methods based on material, geometry, and defect type.

Lesson 3 • Statistical Process Control

Applies control charts, process capability indices, and sampling plans to monitor production quality. Enables early detection of process drift before nonconforming parts are produced.

Lesson 4 • Aerospace Quality Management Systems

Introduces quality management frameworks, first-article inspection, and supplier quality requirements. Connects quality system elements to airworthiness and customer approval processes.

Lesson 1 • Chemical Conversion and Anodising

Explains chromate conversion, phosphoric acid anodise, and sulphuric acid anodise for aluminium corrosion protection. Links coating weight and adhesion to subsequent paint or bond performance.

Lesson 2 • Aerospace Paint and Primer Systems

Teaches primer selection, topcoat application, and cure verification for exterior and interior aerospace finishes. Connects film thickness and adhesion to corrosion and erosion protection.

Lesson 3 • Thermal Barrier and Oxidation Coatings

Addresses thermal barrier coatings and oxidation-resistant coatings for turbine hot-section components. Links coating microstructure to thermal cycling life and spallation resistance.

Lesson 4 • Surface Treatment Process Control

Covers bath chemistry monitoring, process parameter logging, and periodic test panel requirements. Ensures consistent coating quality through disciplined process control practices.

Lesson 1 • Production Scheduling and Capacity Planning

Covers master production scheduling, capacity requirements planning, and constraint management for aerospace programmes. Balances demand variability with available resources and lead time targets.

Lesson 2 • Overall Equipment Effectiveness

Measures availability, performance, and quality rate to compute OEE for aerospace production equipment. Uses OEE data to prioritise autonomous and planned maintenance activities.

Lesson 3 • Kanban and Pull System Design

Designs kanban loops, supermarket sizing, and replenishment triggers for aerospace component flow. Reduces work-in-process inventory while maintaining on-time delivery.

Lesson 4 • Setup Reduction and Quick Changeover

Applies single-minute exchange of die methodology to reduce machine changeover time in aerospace cells. Converts internal setup steps to external activities to maximise spindle uptime.

Lesson 1 • Additive Manufacturing for Aerospace Parts

Covers powder bed fusion, directed energy deposition, and binder jetting for metallic aerospace components. Addresses design for additive, support strategy, and post-processing requirements.

Lesson 2 • Industrial Internet of Things in Production

Connects sensors, edge computing, and data analytics to monitor machine health and process quality. Enables predictive maintenance and real-time process adjustment in aerospace shops.

Lesson 3 • Digital Twin and Model-Based Manufacturing

Applies digital twin concepts to simulate, monitor, and optimise manufacturing processes in real time. Links as-designed, as-planned, and as-built data to close the manufacturing feedback loop.

Lesson 4 • Robotics and Automated Assembly

Examines robotic drilling, fastening, and inspection systems deployed in aerospace final assembly. Evaluates robot selection, end-effector design, and integration with quality systems.