AEROSPACE MANUFACTURING SERVICES

Our aerospace manufacturing services include design and engineering, prototyping and mockups, certification and testing, and production and repair. Let’s briefly examine each of these.

Design & Engineer

We deliver specialized and highly customized aerospace engineering services with the efforts and dedication of over 300 engineers and designers experienced in plastic, metal, and composite product design.

 

Our team has designed 4 families, with 25 different model numbers, of TSOA seats and divans that are in service today.

Two concept aerospace seats for the business jet seating market made by aerospace manufacturing services Interior of a business jet appointed in leather made by aerospace manufacturing services
Interior of a business jet appointed in leather made by aerospace manufacturing services

We deliver specialized and highly customized aerospace engineering services with the efforts and dedication of over 300 engineers and designers experienced in plastic, metal, and composite product design.

 

Our team has designed 4 families, with 25 different model numbers, of TSOA seats and divans that are in service today.

Prototyping & Mockups

Using RCO’s end-to-end suite of capabilities we are able to provide our customers with full scale interior and exterior mockups utilizing the latest technology and material types. We have dedicated well over 7,000 sq ft of build space and can flex space to accommodate private build areas for classified programs.

 

Our flexibility to develop virtually any prototype in our own facilities with speed and quality allows us both scalability and reliability – two unique capabilities that give us a distinctive edge in delivering aerospace manufacturing services for diverse clients.

 A mocked up airplane fuselage sits in RCO's shop made by aerospace manufacturing services A full size airpane fuselage mocked up by RCO made by aerospace manufacturing services
 A mocked up airplane fuselage sits in RCO's shop made by aerospace manufacturing services

Using RCO’s end-to-end suite of capabilities we are able to provide our customers with full scale interior and exterior mockups utilizing the latest technology and material types. We have dedicated well over 7,000 sq ft of build space and can flex space to accommodate private build areas for classified programs.

 

Our flexibility to develop virtually any prototype in our own facilities with speed and quality allows us both scalability and reliability – two unique capabilities that give us a distinctive edge in delivering aerospace manufacturing services for diverse clients.

Certification & Testing

RCO Certification Dept. is well versed in all facets of FAA seat and divan TSO approval processes; including static, dynamic, and flammability test plans.

 

Staff DMIR, along with multiple supporting inspectors, supports FAA conformities and FAIs.

 

We perform durability testing, static testing, fatigue testing, and environmental chamber testing in our  25,000 sq ft A2LA accredited mechanical test lab.

 

All of our dynamic testing takes place in FAA-approved labs like NIAR at WSU.

 

With comfort engineering, we focus on addressing comfort challenges – a key factor for all flight passengers, be it a business jet or commercial airline.

 

 

RCO's Robostand product tests an aerospace seat made by aerospace manufacturing services RCO's Robostand product tests an aerospace seat made by aerospace manufacturing services
RCO's Robostand product tests an aerospace seat made by aerospace manufacturing services

RCO Certification Dept. is well versed in all facets of FAA seat and divan TSO approval processes; including static, dynamic, and flammability test plans.

 

Staff DMIR, along with multiple supporting inspectors, supports FAA conformities and FAIs.

 

We perform durability testing, static testing, fatigue testing, and environmental chamber testing in our  25,000 sq ft A2LA accredited mechanical test lab.

 

All of our dynamic testing takes place in FAA-approved labs like NIAR at WSU.

 

With comfort engineering, we focus on addressing comfort challenges – a key factor for all flight passengers, be it a business jet or commercial airline.

 

 

Production and Repair

RCO Aerospace has a dedicated seat manufacturing facility with the expertise and capabilities to take on any program. We produce over 80 percent of the seat components in-house for our production seat programs. Our facility also touts an EASA approved FAA and Certified 145 repair station with specialization in seat and aerospace component repairs.

 

A lot goes into manufacturing one final product. We produce and assemble thousands of different parts made from several materials. Yet our in-house production teams have routinely exceeded clients’ expectations by manufacturing everything, from small parts to robust, high-quality components with precision, regardless of the size of the production project. Currently, we’re delivering aerospace manufacturing services that include production as well as services for a variety of aircraft seats for a major business jet manufacturer.

RCO Aerospace's manufacturing facility made by aerospace manufacturing services A worker at RCO aerospace assembles a seat in our manufacturing facility made by aerospace manufacturing services
RCO Aerospace's manufacturing facility made by aerospace manufacturing services

RCO Aerospace has a dedicated seat manufacturing facility with the expertise and capabilities to take on any program. We produce over 80 percent of the seat components in-house for our production seat programs. Our facility also touts an EASA approved FAA and Certified 145 repair station with specialization in seat and aerospace component repairs.

 

A lot goes into manufacturing one final product. We produce and assemble thousands of different parts made from several materials. Yet our in-house production teams have routinely exceeded clients’ expectations by manufacturing everything, from small parts to robust, high-quality components with precision, regardless of the size of the production project. Currently, we’re delivering aerospace manufacturing services that include production as well as services for a variety of aircraft seats for a major business jet manufacturer.

AEROSPACE COMPONENT CAPABILITIES

Composites

  • STRUCTURAL
  • NON STRUCTURAL
  • SHORT CYCLE TIME
  • SMC CHOPPED CARBON FIBER
  • REDUCED OR ELIMINATED POST-PROCESSING
  • PRE-PREG STRUCTURAL COMPONENTS
  • VARYING PART THICKNESS
  • COMPLEX PART SHAPES
  • INTEGRATED FASTENERS AND STIFFENERS
  • STRUCTURAL INTEGRITY
A concept aerospace seat with carbon fiber and leather made by aerospace manufacturing services A carbon fiber footrest assembly for an aerospace seat made by aerospace manufacturing services
A concept aerospace seat with carbon fiber and leather made by aerospace manufacturing services
  • STRUCTURAL
  • NON STRUCTURAL
  • SHORT CYCLE TIME
  • SMC CHOPPED CARBON FIBER
  • REDUCED OR ELIMINATED POST-PROCESSING
  • PRE-PREG STRUCTURAL COMPONENTS
  • VARYING PART THICKNESS
  • COMPLEX PART SHAPES
  • INTEGRATED FASTENERS AND STIFFENERS
  • STRUCTURAL INTEGRITY

Foam Components

After 30 years of pouring foam for our automotive customers, we are now perfecting this process for the aerospace industry.

 

We can pour polyurethane directly into a mold and have a finished pad in less than 10 minutes.

 

If CAD data is not available and the turnaround time is tight, we can hand shape foam pads to any contour or hardness.

 

On the other hand, if CAD data is available we can use our CNC machines to cut multiple shapes of varying hardness.

 

Equipped with both expertise and advanced machinery for milled and molded foam work, our team has continuously excelled in the creation of foam cushions and backs for premium seating modeled on innovative aerospace component designs.

Foam blocks used for aerospace seating made by aerospace manufacturing services A worker operates a molded foam machine at RCO engineering made by aerospace manufacturing services
A worker operates a molded foam machine at RCO engineering made by aerospace manufacturing services

After 30 years of pouring foam for our automotive customers, we are now perfecting this process for the aerospace industry.

 

We can pour polyurethane directly into a mold and have a finished pad in less than 10 minutes.

 

If CAD data is not available and the turnaround time is tight, we can hand shape foam pads to any contour or hardness.

 

On the other hand, if CAD data is available we can use our CNC machines to cut multiple shapes of varying hardness.

 

Equipped with both expertise and advanced machinery for milled and molded foam work, our team has continuously excelled in the creation of foam cushions and backs for premium seating modeled on innovative aerospace component designs.

Metal Components

RCO has extensive metalworking metal working capabilities to support the aerospace industry. Our CNC department houses milling machines, ranging from 3 axis to 5 axes and are dedicated to machining aluminum components for structural and aesthetic functions in aerospace interiors. In addition, we design and build our own dies, to stamp out lightweight aluminum and high strength steel components for seat structures, and other interior assemblies.

Machined aluminum components for an aerospace seat made by aerospace manufacturing services A worker assembles seats in RCO aerospaces production manufacturing facility.
A worker assembles seats in RCO aerospaces production manufacturing facility.

RCO has extensive metalworking metal working capabilities to support the aerospace industry. Our CNC department houses milling machines, ranging from 3 axis to 5 axes and are dedicated to machining aluminum components for structural and aesthetic functions in aerospace interiors. In addition, we design and build our own dies, to stamp out lightweight aluminum and high strength steel components for seat structures, and other interior assemblies.

Plastic Components

We've been producing rapid prototype parts for the automotive industry since 1990. Using our FDM technology we can produce exact copies of your CAD file overnight, in a variety of materials. Once a part is made we build silicon molds which enable us to hand pour additional copies at a fraction of the cost. From the FDM we can also build small to large injection molds that can produce well over 20,000 parts.

A plastic injection molded component made by aerospace manufacturing services A fused deposition modeled (FDM) plastic component rapid prototyped in RCO's facility made by aerospace manufacturing services
A fused deposition modeled (FDM) plastic component rapid prototyped in RCO's facility made by aerospace manufacturing services

We've been producing rapid prototype parts for the automotive industry since 1990. Using our FDM technology we can produce exact copies of your CAD file overnight, in a variety of materials. Once a part is made we build silicon molds which enable us to hand pour additional copies at a fraction of the cost. From the FDM we can also build small to large injection molds that can produce well over 20,000 parts.

EXISTING TSOS

Electro Hydraulic Powered Single

Electro Hydraulic Powered Single made by aerospace manufacturing services

Electrical Assist Manual Single

A leather appointed aerospace seat for a business jet made by aerospace manufacturing services

Double Configuration

A double seat configuration for a business jet made by aerospace manufacturing services

Divan

A leather appointed aerospace Divan made by aerospace manufacturing services
A high end business jet aerospace seat.
A leather appointed aerospace seat for a business jet.
A double seat configuration for a business jet.
A leather appointed aerospace Divan.
A high end business jet aerospace seat.
A leather appointed aerospace seat for a business jet.
A double seat configuration for a business jet.
A leather appointed aerospace Divan.

CUSTOM DIVANS

A custom L shaped divan for a business jet. A custom L shaped divan for a business jet made by aerospace manufacturing services
L-shaped Divan

Specifically designed for large business jet installations.
A custom divan for a business jet made by aerospace manufacturing services checkered-divan329x239
Certification

Certification can be completed with inflatable shoulder restraints and leg flail.
Twin bed

Power or manual option available to berth twin bed.
Storage Options

Lower compartment available with optional drawers, doors, or storage boxes.

 Our Place in the Aerospace Engineering Industry

Historically, leading jet manufacturing brands were limited to just a few seat manufacturers. When they sought out new, out-of-the-box out of the box aircraft seat manufacturers, they found RCO Engineering – a leading manufacturer in the automotive industry – who has been at the forefront of innovation in seat manufacturing technology.

 

Our reputation in the automotive industry and our expertise with lightweight materials uniquely positioned us to not only provide aerospace manufacturing services but also meet and exceed the aerospace industry’s stringent aesthetic, functional and design requirements.

 

Today, we’re proud to be a trusted partner for aerospace design, engineering, testing and manufacturing. You’ll find RCO created seating high above the clouds ranging from the exceptionally comfortable foam products of commercial aircraft, to the extremely custom VIP seating of business jets.

 

RCO Engineering is proud to have a place in the aerospace composite manufacturing and engineering industry. Our custom L-shaped divan for business jets offers unparalleled comfort and style that is perfect for any large jet installation. Contact us today to learn more about our products and how we can help you with your aerospace manufacturing needs.

AS9100, ISO9001, ISO17025, ISO14001, FAA CERTIFIED 145 REPAIR STATION #2RCR028C

RCO Aerospace Official