Sunnen

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.

“Our machines are equipped with highly precise, intricate feed and control systems, which has been made possible by our in-house expertise and advanced technology,” says Dan Conner, Business Development Manager. “This allows us to meet the tightest tolerances with ease and provide our customers with efficient solutions.”

How does Sunnen coordinate multidisciplinary engineering to deliver custom systems that maintain tight tolerances?

Many of Sunnen’s systems are custom-built, where a dedicated team of engineers, including electrical, mechanical, and software collaborate to design, tailor processes and meet the complexities of every project. To maintain tight tolerances throughout production, the company also integrates robots, custom fixturing, and in-process air gauging.

What enables Sunnen to deliver extreme accuracy through automated systems without sacrificing performance?

For every custom project, the engagement process typically starts with a customer visit. A sales engineer, along with a mechanical or in-house expert, visits the customer to assess the product, understand their needs, and discuss requirements in person. The direct interaction ensures alignment and clarity that provides better insights than meetings or shared prints.

A prime example of this approach in action can be seen with hydraulic spool valves, which require tolerances as tight as 15 to 20 millionths of straightness for optimal performance. Historically, these valves were hand-lapped by highly skilled operators, a process that could take hours, using abrasive paste to repeatedly refine the part until it met the required specs.

Recognizing the dearth of skilled labor, Sunnen introduced an automated lapping machine. It applies lapping paste, measures the part repeatedly and adjusts to meet the specified tolerances. What used to take several hours is now done in 30 to 45 minutes, significantly reducing time and reliance on manual labor while maintaining precision.

How is Sunnen evolving its precision capabilities to meet future aerospace and defense production demands?

Looking ahead, the company is constantly seeking for new technologies, introducing exotic metals, carbon fibers, and other advanced materials to enhance product lifespan and performance. The focus is to stay ahead of these changes, keeping up with industry trends and understanding the evolving materials being tested. Sunnen is also working towards AS9100 certification, strengthening the commitment to aerospace by ensuring adherence to strict protocols, documentation, and process standards.

Today, Sunnen proves to be the pathfinder to the enduring challenge of tightest tolerance, acting as the blueprint for precision in aerospace and defense. With a relentless pursuit of safety, quality and compliance, it is setting the benchmark for tomorrows most critical missions.