CNC MACHINING FOR SPACE PROGRAMS

Precision CNC Machining for Space Applications

Space is the operating environment least tolerant of manufacturing error. Components for satellites, launch vehicles, and space systems programs carry requirements that most machine shops cannot consistently meet, not because the geometry is always complex, but because the documentation, material traceability, and process discipline required are at a level most shops do not sustain.

Carr Machine & Tool is an AS9100D-certified, ITAR-registered precision CNC machine shop that produces components for space applications from Elk Grove Village, Illinois. We machine structural components, satellite hardware, ground support equipment, and launch-related assemblies for space prime contractors and their subcontractors, with the quality system infrastructure to support your program’s requirements.

CERTIFICATIONS

ITAR Registered

AS 9100D Certified

CMMC - In Progress

WHAT SPACE PROGRAMS REQUIRE

Space programs place requirements on a machining supplier that go beyond drawing conformance. Before selecting a machining partner for space work, procurement teams typically need to verify:

Material Traceability: Every piece of raw material used in a space component must be traceable to heat, lot, & a certified material test report. Our quality system maintains this traceability from raw stock receipt through final shipment.
Process Documentation: How a part was machined is as important as its final dimensions. Our job travelers document the process plan, tooling, setup sheets, & inspection points for every operation.
Dimensional Verification: Many space components carry tight tolerance callouts that require CMM verification rather than hand gauging. We have CMM inspection capability & produce dimensional inspection reports.
First Article Inspection Reports: New programs receive complete FAIRs per your program requirements, including balloon drawings, material certifications, & actual measured values for every controlled dimension.
Configuration Control: We machine to your drawing and revision level. Any drawing change results in an updated process plan and, where required, a new first article. We do not substitute materials or deviate from your print without documented authorization.
ITAR Compliance: Many space programs involve ITAR-controlled technical data and hardware. We are registered with the DDTC under ITAR, which allows us to receive controlled drawings, handle export-sensitive data, and produce hardware for programs operating under ITAR jurisdiction.

SPACE COMPONENT MACHINING CAPABILITIES

Structural Components for Satellite and Spacecraft: We machine structural panels, brackets, frames, and fittings for satellite bus structures and spacecraft assemblies. These components typically require tight flatness, perpendicularity, and true position callouts with CMM verification.
Thermal and Optical Instrument Hardware: Precision housings, mounting plates, and optical benches for instruments require both dimensional accuracy and surface finish control. We machine these components with specific attention to surface finish callouts and flatness requirements that affect instrument alignment.
Propulsion System Components: Manifolds, valves, orifice plates, and pressure hardware for space propulsion systems require material certifications, full traceability, and verified dimensional conformance. We machine these components from materials that meet your program’s pressure and temperature requirements.
Launch Vehicle Hardware: Brackets, adapters, and structural hardware for launch vehicle systems require high-strength materials machined to tight tolerances with complete process documentation. We have experience with the structural hardware categories common to small and medium launch vehicle programs.
Ground Support Equipment: Precision tooling, test fixtures, handling equipment, and interface hardware for space system GSE requires the same material traceability and dimensional accuracy as flight hardware.

Materials for Space Applications

Space hardware commonly requires materials with exceptional strength-to-weight ratios, thermal stability, and resistance to the vacuum and radiation environment.

Titanium Alloys: Primary structural material for weight-critical space hardware
2024 and 7075 Aluminum: Satellite bus structures, adapters, and thermal hardware
Inconel 625 / 718: High-temperature propulsion and engine-adjacent components
17-4 PH & 15-5 PH Stainless Steel: High-strength corrosion-resistant hardware
A286: Fasteners and high-temperature structural fittings
Copper Alloys: Thermal interface components and electrical hardware
PEEK / Ultem / Vespel: Lightweight, thermally stable non-metallic structural components

Material selection is governed by your drawing specification. We source materials from certified suppliers and document all certs against your job traveler.

Working with Carr Machine & Tool

Space programs typically begin supplier qualification earlier than other industries, and for good reason. We support that process through:

Supplier Qualification Documentation: Quality manual, AS9100D certificate, ITAR registration, representative first article reports, and equipment calibration records are available upon request.
Pre-Quote DFM Review: We review your drawing before quoting and flag any features where our process capability should be confirmed against your tolerance stack before the program begins.
Prototype Through Production Continuity: Prototype and engineering development work runs through the same quality system as production hardware. There is no quality reset when you move from development to production quantities.
Open Communication During Production: We communicate schedule status proactively rather than waiting for a check-in call. If something affects your delivery, you hear from us before you are impacted.

FREQUENTLY ASKED QUESTIONS

Is Carr Machine & Tool qualified to machine flight hardware for space programs?

We are AS9100D certified and ITAR registered, which are the standard entry-level requirements for space machining suppliers. Specific program qualification requirements vary by prime contractor and program. We support your qualification process with documentation including our quality manual, certificate, ITAR registration, and representative inspection records.

Can you provide full material traceability for space parts?

Yes. Material certifications are sourced from qualified suppliers, documented on job travelers, and retained in our quality records. Full traceability from heat and lot to finished part is maintained for all space program work.

Do you produce AS9102 first article inspection reports?

We produce first article inspection reports with balloon drawings and actual measured values for all controlled dimensions. If your program requires full AS9102 format, inform us during the quoting process and we will confirm format compatibility or align our documentation to your requirements.

How do you handle ITAR-controlled drawings for space programs?

We are registered with the DDTC under ITAR. ITAR-controlled drawings are handled within our established access control procedures, and our team members who access controlled data are identified and managed per our ITAR compliance program.

Do you machine very small or very thin space components?

Yes, though capability depends on specific geometry, material, and tolerance stack. Submit your drawing and we will assess fixture strategy, tooling approach, and whether your tolerance requirements are achievable on your specific part geometry.

Do you work with space customers outside of Illinois?

Yes. We ship components to space program customers across the United States. Drawings are submitted electronically, and finished parts ship via freight to your facility or designated receiving location.

Partner with CARR Machine & Tool

Submit your supplier qualification questionnaire, NDA, and initial drawings. We will return completed documentation, review your initial drawings for any process concerns, and begin the quote process in parallel. We understand space procurement timelines and will prioritize responses accordingly.