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Engineers in defense and aerospace often face a problem that looks deceptively simple on paper: they need something to move from Point A to Point B under load, without fail. A cylinder must push, pull, lift, or position a mass and behave predictably across temperatures, pressures, velocities, and alignments that no textbook can fully capture. These systems sit at the heart of launch infrastructure, missile elevation platforms, mobile bridging equipment, naval mechanisms, industrial press machines, and civil structures. Yet the actuators that drive them are rarely as straightforward as their linear motion implies. Behind every stroke lies a volatile combination of physics, safety, and environmental exposure that makes the act of “going in and out” a far more sophisticated engineering challenge. For decades, defense contractors and aerospace integrators have struggled to find cylinder manufacturers willing or able to engineer around these realities. Off-the-shelf units rarely survive the loads. Commodity suppliers lack the testing capacity. High-production manufacturers cannot adapt their processes to the slow, iterative work needed for custom, mission-critical actuation. The result is a quiet but persistent bottleneck: programs stall, launch hardware underperforms, mobile military systems degrade faster than expected, and engineering teams search for suppliers who can design not just a component but a solution. Innovative Hydraulics, LLC was built for this problem. Rather than compete in the crowded space of standard catalog cylinders, the company defined itself around a single conviction: complex motion deserves complex engineering. Where other manufacturers seek volume, Innovative Hydraulics seeks difficulty. Where others deliver a part, the company delivers a piece of an engineered system. And where many suppliers hope customer requirements conform to their production capabilities, Innovative Hydraulics reshapes its processes to meet those requirements head-on. From the outset, the company positioned itself at the intersection of engineering rigor, manufacturing discipline, and environmental resilience. Its work ranges across aerospace, defense, industrial presses, heavy mobile equipment, and civil engineering, yet every project they accept carries a similar DNA: unusual size, unusual load, unusual environment, or unusual precision. These are the cylinders that cannot fail.
Tolerance, in the world of aerospace and defense, has become the industry’s highest-stakes game. Even the slightest deviation can make the difference between mission success and catastrophic failure, whether in the skies, space, or on the battlefield. Parts need to fit with laser precision where straightness, bore geometry, and surface finishes align with unyielding accuracy. But here is the catch: the people who once performed this intricate work manually are now a vanishing class. Many of these experts are nearing retirement, and there aren’t enough younger workers trained to replace them. The result is a talent shortage in an industry that cannot afford to compromise on excellence. Through the power of digital innovation, Sunnen has emerged as a key player in bridging the gap. Experts in navigating the tightest tolerances, the company blends automation with the precision that aerospace and defense demands, without compromising on quality or performance. How is Sunnen responding to rising precision demands in aerospace and defense as skilled labor declines? Specializing in aircraft hydraulic components, it works in tandem with partners that handle aircraft fuel supply systems. The same precision expertise extends to defense applications, where it provides advanced honing solutions for military components, including pistol, rifle, and cannon barrels. By achieving tight control over dimensional tolerances and surface finishes the company enhances the accuracy, durability, and repeatability of firearms and other critical military equipment.
AIMS has long worked at the center of airline operations, where complexity steadily increases as networks expand, fleets evolve, and regulatory demands grow. Across the industry, airlines need to balance crew, aircraft, and schedules using a mix of specialized tools and manual processes. While these approaches have supported growth over time, they can make real-time coordination demanding when legality, availability, and passenger commitments must remain closely aligned. Established in 1983, the company has supported airline operations for more than four decades and has been deployed across 230 airlines worldwide, reflecting sustained relevance in live operating environments. “We have endured because AIMS functions as core operational infrastructure, proven in live airline environments where reliability, compliance and speed are not optional,” says Glen Bethanis, MD, Strategic Planning. AIMS operates as a fully integrated operational system built on a single shared database and flight schedule, serving as one source of truth across the airline. Crew planning and tracking, training, vacation management, aircraft scheduling, maintenance planning, aircraft movement control, and commercial planning all operate from the same real-time data foundation. With no duplication, data transfer, or reconciliation required, updates and decisions propagate instantly across departments. This unified approach enables operations teams to act faster, stay aligned, and make confident decisions based on consistent, accurate information throughout the operation. "That level of integration changes how airlines make decisions,” explains Bethanis. “When every department is working from the same operational reality, optimization becomes practical.” AIMS uses high-speed optimizers as the primary engine for efficiency, with AI and ML applied where practically appropriate. Schedules are constructed so all flights are covered, spare capacity remains available, and additional crew or aircraft are not required to absorb growth. In airlines with experienced flight operations teams, these optimizers deliver operating cost reductions of around three percent and savings of up to 15 percent in less automated environments. These efficiencies come from tighter utilization, faster planning cycles, and less structural inefficiencies without compressing crew margins.
In the defense and aerospace world, technologies are getting smarter, faster and more complex, yet the packaging sector responsible for getting those mission-critical systems safely into the field has barely kept pace. The landscape remains fragmented, tied to regional boundaries, constrained by legacy equipment, and slowed by outdated processes and sluggish quoting cycles. Many providers still treat packaging as foam in a box, even though modern military systems require engineered, MIL-STD-compliant protection capable of absorbing shock, resisting impact, and withstanding temperature extremes, water ingress, dust and transportation abuse. “Integration support is rare. Turnkey solutions are even rarer. And for OEMs running high-volume programs with dozens of unique configurations, the industry offers little consistency, little innovation and even less urgency, and we are here to fix that,” says Mark Rolfes, co-president and CRO at Packaging Strategies Incorporated (PSI). As a U.S.-based, fully integrated design and manufacturing company, Packaging Strategies has redefined what protective packaging can be for military, federally funded and aerospace maintenance programs. It specializes in the design, engineering, fabrication and full-system integration of custom cases that meet program-specific MIL requirements and the real-world demands of field operations. Instead of handing OEMs an empty case and walking away, Packaging Strategies steps into the part of the process most suppliers avoid. Its engineering team develops full protective systems, including shock-mounted assemblies, internal frameworks, harnessing and custom inserts designed to safeguard everything from large military drones to missile components to advanced simulation hardware. And because many customers need more than a container, Packaging Strategies finishes the job by installing all electronics, components and accessories in-house. The result is a fully assembled, field-ready case that the OEM never has to touch. With new investment, upgraded systems, modernized equipment and an ambitious leadership team, the company has positioned itself as the partner that finally closes the gap between the sophistication of today’s defense technologies and the packaging systems required to protect them.
Neuroscience-driven methodology to evaluate 100,000 executives and professionals for future leadership potential and Engineering Talent for the Next Aerospace Frontier In a rapidly evolving world where technology accelerates and industries pivot almost overnight, résumé-based hiring is no longer sufficient, especially in aerospace. What once worked, evaluating candidates based on past experiences and qualifications, no longer captures the dynamic skill sets required. As a result, aerospace companies cannot afford to hire leaders based solely on historical performance. Instead, they need visionaries who can navigate ambiguity, understand emerging technologies, and adapt to new realities. This is where Top Notch Finders steps in, redefining the executive search process with a cutting-edge, neuroscience-powered, AI-driven talent intelligence system. How does Top Notch Finders redefine aerospace executive search beyond traditional résumé-based hiring? For more than three decades, Top Notch Finders has been an integral player in aerospace executive search, helping companies recruit and retain leaders capable of driving the future of the industry. By integrating decades of cognitive science with advanced AI, the firm’s methodology provides a more accurate, forward-looking understanding of leadership potential, focusing not only on what a leader has done but on who they can become in an unpredictable future. Under the leadership of Fernando Espinosa Ramirez, CEO and chief talent officer, the firm has moved beyond traditional hiring practices to create an innovative framework that emphasizes adaptability, cognitive flexibility, and emotional intelligence. “Résumé-driven decisions once made sense, but the world has changed enough to make that approach incomplete,” Espinosa explains. “The complexity of the modern world requires something different: talent that can not only succeed today but is prepared to lead tomorrow.”
Sarah Leeper, Vice President / General Manager, Electronic Systems, Draper
Duane Cornella, Sr. Manager Operations Control Centers, Panasonic Avionics
Lance Lau, Director of Training, CommuteAir
Paul Guerrier, Manufacturing Engineering Manager, Moog Inc[NYSE: MOG-A]
Maurice Jenkins, Chief Innovation Officer, Miami International Airport
Mark Finger, Manager – AOG Response, Delta Air Lines
Andy Mears, Manufacturing Engineering, Sr. Manager - Operations Transformation & Intelligent Factory, Lockheed Martin
Military signature management systems protect sensitive data by ensuring the authenticity, integrity, and accountability of communications in defense operations.
Defense hydraulic cylinder design and manufacturing are evolving with the use of advanced materials, automation, and precision engineering to enhance performance, reliability, and efficiency in modern military operations.
Innovative Engineering Solutions for Tomorrow’s Missions
At the center of this issue, Innovative Hydraulics, recipient of the Top Defense Hydraulic Cylinders Designs and Manufacturer 2026 award, demonstrates how complex motion requires complex engineering. Rather than supplying catalog components, the company engineers highly customized cylinders built to withstand extreme loads, environmental exposure, and exacting tolerances. From modernizing NASA’s crawler transporter systems to supporting demanding defense platforms, its approach integrates design, machining, welding, and testing under one roof to ensure performance where failure is not an option.
Beyond hydraulics, this edition recognizes companies strengthening the industry’s operational backbone. PSI Cases, honored for Military Signature Management Systems of the Year 2026, advances protective packaging into fully engineered, MIL-compliant integration systems that deliver field-ready deployment. AIMS, awarded Top Aviation Crew Management Service 2026, provides airlines with a unified operational platform that aligns crew, aircraft, compliance, and cost control through a single real-time data environment. Sunnen, named Top Aerospace Precision Machine Service 2026, addresses tightening tolerance demands through automated honing systems that reduce reliance on vanishing manual expertise while preserving dimensional accuracy. Meanwhile, Top Notch Finders, Buyers Choice Aerospace Executive Search Company of the Year 2026, introduces neuroscience-validated talent intelligence to identify adaptable, future-ready aerospace leadership.
Complementing these achievements, Shelli Brunswick, CSBJ Women of Influence, at Space Foundation, underscores the expansion of space manufacturing and the urgency of workforce development. Mark Notarfrancesco, Vice President, Industrial Services at Woodward, reinforces the role of tribological science and metrology discipline in extending component life and performance predictability.
Collectively, the organizations featured here reflect a sector advancing through rigor, integration, and forward engineering. The path ahead belongs to those who design for complexity and execute with certainty.
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