Design, Tooling & Machining

Our in-house tooling capabilities specialize in the design and fabrication of precision development and production tooling optimized for high-performance composite manufacturing. By managing and manufacturing the entire tooling package within Eagle, we eliminate external supplier lead times and ensure seamless transition from design to new product introduction (NPI) through to full-rate production. This capability also allows us to quickly and seamlessly maintain or modify tooling and fixturing as may be necessary.

• Resin Transfer Molding (RTM) Dies: High-precision, sealed matched-metal molds engineered to withstand injection pressures and maintain uniform thermal profiles.
• Autoclave Tooling: High-durability molds designed with balanced thermal mass to ensure uniform curing cycles under high-temperature and high-pressure environments.
• Compression Molds: Rigid, high-wear matched dies optimized for high-volume thermoplastic or thermoset compression molding operations.

Bonding & Assembly Fixtures: Heavy-duty, dimensionally stable jigs engineered to maintain critical alignment tolerances during secondary bonding and sub-assembly processes.

Our CNC machining capabilities provide our customers with precision 3, 4 and 5-axis milling and turning capabilities for both metallic and composite flight hardware and assemblies. We process a variety of materials including aircraft aluminums, steels, titanium and carbon fiber composites.  Our multi-axis milling envelopes accommodate parts including engine case and wide body engine case liners. Our CNC turning centers handle components in size up to business jet engine cases to aerospace tolerances, precision and repeatability.  Our in-house machining centers are fully integrated with our design and programming team, ensuring on-time delivery with minimum lead times and seamless DFM.

Metals Machining Capabilities

• Production Machining

• CNC Milling

• CNC Turning

• CMM Inspection

• Laser Part Marking

• Metals Secondary Finishing & Outside Processes

• Anodizing

• Nickel Plating / Black Oxide

• Part Marking

• FPI / Passivation

• Wire EDM

• Laser / Waterjet Cutting

• Mechanical / Chemical Analysis

• Welding

• Heat Treatment / Annealing

• Thermal Spray

• Priming

Our specialized composite machining team leverages decades of aerospace expertise to deliver high-speed milling, turning, trimming, routing, and drilling on complex polymer matrix composite (PMC) components and assemblies. Our experienced technicians use optimized tool geometries and diamond-coated cutters to ensure quality and eliminate common defects such as fiber breakout and delamination. Because our machining, fabrication, and tooling are fully integrated in-house capabilities, we maintain absolute process control over the entire production cycle, drastically reduce customer lead times, maximizing first-pass yield and on-time delivery. By combining this self-reliant workflow with deep technical and processing knowledge, we eliminate external supplier bottlenecks while maintaining full compliance with quality standards, tolerances, and customer specifications.