Products / 01 — Aerostructures
Fully stuffed aerostructures, from development through full rate.
Janicki is an aerostructures supplier and manufacturer, sole-source Tier 1 on a range of platforms. We carry structure from R&D through qualification into full-rate production, delivered as complete assemblies ready to install, with composite structure and monolithic machined titanium and aluminum details from the same floor: fuselage sections, wings, empennage, control surfaces, inlets, doors, ducts, fairings and tanks for manned and unmanned aircraft, advanced air mobility and spacecraft.
Marquee platform
Janicki is a member of the B-21 Raider industry team — the nation's next long-range strike bomber.
What "fully stuffed" means
Structure that ships ready to install.
Janicki delivers the assembly with internal structure, fittings, systems provisions and hardware installed and inspected, also called an equipped structure. The customer's next station starts with a finished unit, not a shell.
Every delivery is tested and certified before it ships: functional and leak checks, Nadcap NDT and metrology, AS9102 first article inspection on new configurations, and a certificate of conformance with the as-built data package for every serial number.
| Primary structure | Skins, frames, bulkheads, spars, ribs |
|---|---|
| Secondary structure | Brackets, fittings, clips, doublers |
| Systems installation | Harness routing, hydraulic and fuel provisions, ECS ducting, mounts and penetrations; continuity and pressure checks before shipment |
| Hardware | Fasteners, inserts, bushings installed |
| Verification | Laser-tracker and scan metrology, Nadcap ultrasonic NDT, digital inspection report and as-built traceability per serial number |
| Test & certification | Functional and leak tests on installed systems, AS9102 first article inspection, certificate of conformance and data package with every unit |
Manned aircraft structure
Fuselage sections, wing and empennage structure, control surfaces, doors and fairings for manned fixed-wing and rotorcraft programs, in composite, metallic and hybrid construction.
Programs run from R&D through qualification into full-rate production without changing suppliers, so qualification hardware and production hardware come from the same line.
Large unmanned aircraft
Complete airframes and major assemblies for large UAVs and drones, delivered fully integrated at production rate, on processes sized for fleet quantities.
Small unmanned aircraft
Small UAV and drone airframes and components where weight and repeatability matter more than size: thin-wall composite structure with the process control to hold weight and geometry across a production run.
Advanced air mobility
Composite fuselage, wing and boom structure for eVTOL and other advanced air mobility aircraft: light, repeatable, with the materials testing and process qualification needed to move from flight test into certified production.
Spacecraft and launch structure
Large-diameter composite structure, fairing and tank hardware, and metallic structure: precision machined fittings, adapters, rings and brackets in aluminum, steel and titanium, for launch vehicles and spacecraft.
Radar models
Full and sub-scale radar models built to the surface accuracy range measurements demand. The model is only as good as its surface, so it is a machining and metrology job before anything else.
Machined on the same 5-axis mills as our tooling, finished, and verified with Leica laser trackers accurate to roughly 0.002 in.
Monolithic titanium and aluminum detail parts
Large-format precision CNC machining of monolithic detail parts, in-house, from titanium and aluminum billets and forgings: bulkheads, spars, frames, longerons, ribs and fittings, each cut from a single piece of stock. The work runs on Janicki's own five-axis (5-axis) gantry mills and horizontal machining centers.
Composite detail parts
Fly-away composite details supplied to customer assembly lines: skins, spars, ribs, frames, doors, ducts, fairings and brackets in carbon fiber (CFRP) and fiberglass, including honeycomb- and foam-cored sandwich panels where the design calls for it. Parts are laid up by hand or by automated fiber placement, cured in autoclave or out of autoclave, trimmed and drilled on 5-axis mills, and inspected with Nadcap-accredited NDT before they ship.
How we build it
Layup to inspection, in-house.
Janicki is an aerospace composites manufacturer with composite fabrication, precision CNC machining, bonding, assembly and inspection on one floor, building major assemblies, sub-assemblies and detail parts. Programs come to us as build-to-print contract manufacturing against a customer’s design, or earlier, at R&D and process development.
Layup
Hand layup of carbon fiber prepreg with laser ply projection, automated fiber placement and automated layup in access-controlled clean rooms.
Cure
Six autoclaves to 18′ diameter and 50′ long, at up to 160 psi and 550°F; oven and out-of-autoclave processes; resin infusion.
Trim, drill and machine
Five-axis CNC trim and drill of cured structure to ±0.005 in on mills to 100 ft; hole patterns and interfaces machined to net for determinate assembly.
Metallic structure
Large monolithic titanium and aluminum detail parts machined in-house from billets and forgings, plus steel details, welded assemblies and hybrid metal-composite structure.
Bond and assemble
Adhesive bonding, mechanical assembly, systems installation and interface control in jigs we build ourselves.
Inspect
Nadcap-accredited NDT, laser-tracker and scan metrology, and CMM, on the same floor as the work.
Tooling
Masters, molds, mandrels and fixtures built in-house, so tooling lead time is ours to control.
R&D and process development
Materials and process lab for coupon testing, cure-cycle development and qualification articles; thermoplastic in-situ consolidation development with Electroimpact and Toray.
Program experience
Structures that are flying today.
A selection of the platforms carrying Janicki-built structure right now.
MQ-9B SkyGuardian
Composite airframe structure for General Atomics' MQ-9B SkyGuardian and SeaGuardian, produced at rate across U.S. and allied fleets.
F-35 Lightning II
Sole-source provider of drill and trim for determinate assembly since 2010.
Stratolaunch Roc
Roughly 40% of the structure, by weight, of the widest-wingspan aircraft ever flown, on tooling from the same floor.
Start a program
Bring us the structure.
Send the platform, rate and schedule and we will propose a tooling approach, a build plan and an inspection plan.