Aerospace Roll Forming Service

Why Choose Our Aerospace Roll Forming Service?

Our roll forming process follows strict airplane rules to make safe parts that won’t fail during flight. When you pick Istar Machining, you get:

• AS9100 & NADCAP-Certified parts that meet all flying safety rules
• Super exact measurements (within ±0.005″) for perfect fitting parts
• Fast production from one test piece to thousands
• All-in-one service with punching, welding, and coating done together
• Weight-saving designs that help planes use less fuel

Materials We Use

We work with special aerospace-grade metals that can handle the extreme conditions planes face:

Our titanium CNC machining skills also help us make complex titanium parts that work perfectly with our roll-formed components.

What We Can Make

Our aerospace roll forming service creates many important airplane parts:

Aircraft Wing Stringers

These long, thin parts run inside wings to make them strong without adding much weight. We form them from high-strength aerospace alloys that won’t break even after thousands of flights. Our stringers are trusted by major aircraft makers for their perfect fit and long life.

Fuselage Frames & Bulkheads

The curved frames that give an airplane’s body its shape must be precise and strong. Our roll-formed frames resist cabin pressure changes and protect passengers. Each part comes with zero-defect guarantee because lives depend on them.

Engine Nacelles & Ducting

The smooth covers around jet engines need perfect shapes to help air flow correctly. Our ultra-tight tolerances make sure these parts reduce drag and help save fuel. We use computer-controlled forming systems for the most exact shapes possible.

Flight Control Surfaces

Parts like ailerons and flaps that control how a plane flies must work perfectly every time. Our roll-formed flight controls maintain their strength while making assembly faster with built-in spots for fasteners. We can make test pieces in just 3 weeks!

Our Roll Forming Process

We follow a careful step-by-step process for every aerospace part:

1. Design Collaboration – We work with your engineers to make sure your part can be roll formed perfectly
2. Material Prep – We cut aerospace-grade metal sheets to precise widths
3. Multi-Stage Forming – Special tools slowly bend the metal into complex shapes without weakening it
4. Testing & Inspection – Every part is checked with special tools to make sure it’s perfect
5. Finishing & Certification – Parts are cleaned, coated if needed, and come with paperwork showing they meet all requirements

For projects needing both roll forming and complex cutting, our 5-axis machining service creates perfect finished parts.

Technical Details

Our aerospace roll forming service can handle:

• Material Thickness: From very thin 0.020″ to thicker 0.250″ (0.5mm to 6.35mm)
• Part Lengths: Up to 40 feet (12 meters) in one continuous piece
• Surface Finishes: Raw metal, anodized, or chemical-treated per aerospace standards
• Compliance: Meets ITAR, DFARS, and REACH requirements

Working With Spacecraft Parts

We also make roll-formed parts for satellites and space vehicles. These parts must follow ITAR security rules and have complete tracking from raw material to finished part. Our roll forming for spacecraft ensures compliance with all space industry standards.

Prototyping & Testing

Need to test a new design? Our rapid CNC machining and roll forming services can create test parts in as little as 3 weeks. We offer:

• Fast prototype creation for testing new designs
• Custom tooling made specifically for your part
• Computer simulation to predict how the metal will behave
• Material testing to ensure performance

Why Customers Choose Istar Machining

Our aerospace customers keep coming back because we offer:

• 50+ Years Combined Experience in making aerospace parts
• Zero-Defect Guarantee backed by automatic inspection systems
• Fast Turnaround even for complex shapes
• Complete Documentation for all aerospace quality requirements

When your projects need both roll forming and aerospace CNC machining, we provide seamless integration between services.

Get Started Today

Ready to make your aerospace project take flight? Submit your design files today for a free review and quote within 24 hours.

Our engineers will check if your part can be roll formed and suggest any changes that might make it stronger, lighter, or less expensive to produce.