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Assembly


Landing gear and hydraulic components are assembled in special rooms with controlled temperature and humidity, using adequate tools and devices according to the technical specifications of the products.
The assembly operations are carried out in "Lean Manufacturing Conditions".
HTMLText_B2533758_8581_17B1_41C4_E4D3473699E7.html =
Blasting


Another machine available here is the glass bead blaster. By bombarding the workpiece with glass beads, compressive stresses are induced on the surface of the workpiece. This process increases the fatigue and corrosion resistance of the manufactured parts.
HTMLText_05365C82_8581_FA90_41E0_3503A56FF636.html =
Civil and Military Hangars


Near the civilian hangars we have military hangars where we perform maintenance for various types of military aircraft and helicopters such as F-16s and S-70 Black Hawk helicopters.
HTMLText_F891CB95_8581_1EB0_41E0_7F8C61400169.html =
Coordinate measuring machines


Everything is controlled and measured by using coordinate measuring machines (CMM). Here the surface of the part can be scanned and compared with the 3D model. This is the stage of the manufacturing cycle where the product is validated.
HTMLText_A9DA2957_8587_FBBF_41D7_5DC27BAA6B1C.html =
Grinding robot


The industrial robots used in manufacturing processes increase the process consistency and boost productivity. One such robot is our grinding robot, which is used to increase the quality of the surface obtained, to obtain the required roughness, to ensure continuity in operation and to avoid exposing operators to a harmful working environment.
HTMLText_074FDE3F_8581_79EF_41E0_99F58E91DFA8.html =
Hydroforming


The aluminium alloy sheets are pressed into the required shape. This process is made possible by the hydroforming process, where, depending on complexity and configuration, a maximum force of 800 bars is applied to the blank to copy the shape of the mould.
This allows the production of parts up to 1800 mm long. From here the parts can be routed to other processes in the production flow to complete the requirements specified for the manufactured parts.
HTMLText_9CD558DF_8581_1AAF_41D2_77DA2335A27D.html =
Integrex Machines


The 5-axis CNC machining centres for milling and turning operations are programmed by our fellow programming engineers using CAD-CAM programming languages and operated for optimum efficiency by our fellow operators. From here the parts are transferred to other work points along the manufacturing flow.
HTMLText_F8EC5909_858F_1B93_41D8_DD914E2E22DD.html =
Routing machines


The routing plans are made by our colleagues in the specialised process engineering compartments to create the developed shape of the parts. This optimises the material consumption.
HTMLText_FCD2E39D_858F_0EB0_4189_E6BCFC875931.html =
Shroudbox assembly line


A complex assembly that is part of the aircraft wings is the Shroud Box.
All the component parts are manufactured in Aerostar and the product is assembled in jigs on the assembly line, after which the final product, integrally made in Aerostar, is packed and delivered to our customer. So far, more than 5500 of these kits have been delivered for Airbus A320/A321 aircraft.
HTMLText_7DB2E382_7065_343F_41C2_951F708170F1.html =
AEROSTAR S.A.
www.aerostar.ro
aerostar@aerostar.ro
Tel.: +40 234 575 070
HTMLText_A3FF7784_8032_8D0C_41CF_60E9BD304BFB.html =
Administrative Building


AEROSTAR was founded in 1953 with the initial purpose of carrying out maintenance and repair of military aircraft belonging to the Romanian Air Force.


Meanwhile, Aerostar's footprint has expanded globally, and we have a high level of expertise in the aerospace field, with a team of 2000 employees.
HTMLText_A2C7887A_8035_8304_41BA_C16322292D94.html =
Aerostar Gate 1


Welcome to the virtual tour of Aerostar!


Now you can see our production facilities up close and understand our standards and dedication to maintaining the highest quality.


We have broad experience in the aviation and defence industry, manufacturing complex structural parts, landing gear, hydraulic systems and performing maintenance services for commercial & military aircraft, helicopters and rocket launchers.


Enjoy your virtual visit to the Aerostar factory! Let's begin our tour!
HTMLText_A32B904C_8032_831C_41D4_804984732A60.html =
Aerostructeres and Subansamblies Facility


Let's go to the aerostructure and subassembly facility where simple and complex sheet metal parts are made for civil aircraft or even space launch vehicles.


Millions of parts have been delivered from this factory to our customers Airbus, Boeing, Bombardier and others.
HTMLText_A3468C82_8035_8304_41B2_A75E31C637DE.html =
Civil Aviation Maintenance Hangars


Here we are, in one of the 3 hangars where maintenance is performed for Airbus A320 ceo and neo family and Boeing B737 all series, including MAX - 7/8/9.


In these hangars we perform complex structural repairs, cabin reconfigurations and restorations, structural and avionics modifications and maintenance of composite elements.


In each hangar we can carry out simultaneous activities on 3/4 aircraft.
HTMLText_A3711511_8035_8D04_41D0_57624FB55724.html =
Electronic Systems Facility


The team in the Integrated Electronic Systems department develops and manufactures power supply systems, antenna rotation systems, interface blocks, central processing units for command/control, merging and unified data display.


Moreover, our colleagues provide integrated logistic services for command control, radar and electronic combat systems, from D-level repairs to test benches and complex system integration stations.
HTMLText_A30F9644_8032_8F0C_41DB_6FD466C0BDBC.html =
Hydraulic System and Landing Gear Facility


The first stop on our tour is the Landing Gear and Hydraulic Systems Facility.


This is where the flap actuator cylinders, main and nose leg release cylinders, landing gears and actuators are manufactured, as well as various kits of parts used on aircraft such as Airbus A320/A321, A330, A350, Daher TBM 960, Boeing 787 or Super Puma helicopters.


The parts are made of various types of materials such as hard aluminium, steel, stainless steel, high strength steel, bronze, titanium. begin our tour!
HTMLText_A3381F92_8032_7D04_41A4_7F85035C917B.html =
Non Destructive Testing Line


No defect can pass through!


Non-destructive liquid penetrant testing methods are used to identify hidden cracks, porosity and part integrity throughout the manufacturing flow.


The non-destructive process line is designed for testing with 2 fluorescent penetrant liquids and is equipped with a wash station, a drying oven and a part loading and unloading area.
HTMLText_A3361E8B_8032_7F04_41D0_35A07470F3DA.html =
Special Processes


Corrosion protection is provided by surface coatings. In Aerostar, we use state-of-the-art processes that replace the hexavalent chromium from classic anodizing with sulphuric and tartaric acid anodizing.


After anodizing, the parts are coated with a thin layer of primer and painted with water-based paints.


Drying in the oven at 80 degrees Celsius for about 25 minutes causes the paint layer to polymerise and thus improves the durability of the part and creates a beautiful finish.


Let's not forget quality inspection, a process whereby our colleagues check each part carefully to spot any imperfections.
HTMLText_F90FCBC4_8583_1E91_41BE_85DAC2D4D480_mobile.html =
Assembly


Landing gear and hydraulic components are assembled in special rooms with controlled temperature and humidity, using adequate tools and devices according to the technical specifications of the products.
The assembly operations are carried out in "Lean Manufacturing Conditions".
HTMLText_B2533758_8581_17B1_41C4_E4D3473699E7_mobile.html =
Blasting


Another machine available here is the glass bead blaster. By bombarding the workpiece with glass beads, compressive stresses are induced on the surface of the workpiece. This process increases the fatigue and corrosion resistance of the manufactured parts.
HTMLText_05365C82_8581_FA90_41E0_3503A56FF636_mobile.html =
Civil and Military Hangars


Near the civilian hangars we have military hangars where we perform maintenance for various types of military aircraft and helicopters such as F-16s and S-70 Black Hawk helicopters.
HTMLText_F891CB95_8581_1EB0_41E0_7F8C61400169_mobile.html =
Coordinate measuring machines


Everything is controlled and measured by using coordinate measuring machines (CMM). Here the surface of the part can be scanned and compared with the 3D model. This is the stage of the manufacturing cycle where the product is validated.
HTMLText_A9DA2957_8587_FBBF_41D7_5DC27BAA6B1C_mobile.html =
Grinding robot


The industrial robots used in manufacturing processes increase the process consistency and boost productivity. One such robot is our grinding robot, which is used to increase the quality of the surface obtained, to obtain the required roughness, to ensure continuity in operation and to avoid exposing operators to a harmful working environment.
HTMLText_074FDE3F_8581_79EF_41E0_99F58E91DFA8_mobile.html =
Hydroforming


The aluminium alloy sheets are pressed into the required shape. This process is made possible by the hydroforming process, where, depending on complexity and configuration, a maximum force of 800 bars is applied to the blank to copy the shape of the mould.
This allows the production of parts up to 1800 mm long. From here the parts can be routed to other processes in the production flow to complete the requirements specified for the manufactured parts.
HTMLText_9CD558DF_8581_1AAF_41D2_77DA2335A27D_mobile.html =
Integrex Machines


The 5-axis CNC machining centres for milling and turning operations are programmed by our fellow programming engineers using CAD-CAM programming languages and operated for optimum efficiency by our fellow operators. From here the parts are transferred to other work points along the manufacturing flow.
HTMLText_F8EC5909_858F_1B93_41D8_DD914E2E22DD_mobile.html =
Routing machines


The routing plans are made by our colleagues in the specialised process engineering compartments to create the developed shape of the parts. This optimises the material consumption.
HTMLText_FCD2E39D_858F_0EB0_4189_E6BCFC875931_mobile.html =
Shroudbox assembly line


A complex assembly that is part of the aircraft wings is the Shroud Box.
All the component parts are manufactured in Aerostar and the product is assembled in jigs on the assembly line, after which the final product, integrally made in Aerostar, is packed and delivered to our customer. So far, more than 5500 of these kits have been delivered for Airbus A320/A321 aircraft.
HTMLText_7DB2E382_7065_343F_41C2_951F708170F1_mobile.html =
AEROSTAR S.A.
www.aerostar.ro
aerostar@aerostar.ro
Tel.: +40 234 575 070
HTMLText_A3FF7784_8032_8D0C_41CF_60E9BD304BFB_mobile.html =
Administrative Building


AEROSTAR was founded in 1953 with the initial purpose of carrying out maintenance and repair of military aircraft belonging to the Romanian Air Force.


Meanwhile, Aerostar's footprint has expanded globally, and we have a high level of expertise in the aerospace field, with a team of 2000 employees.
HTMLText_A2C7887A_8035_8304_41BA_C16322292D94_mobile.html =
Aerostar Gate 1


Welcome to the virtual tour of Aerostar!


Now you can see our production facilities up close and understand our standards and dedication to maintaining the highest quality.


We have broad experience in the aviation and defence industry, manufacturing complex structural parts, landing gear, hydraulic systems and performing maintenance services for commercial & military aircraft, helicopters and rocket launchers.


Enjoy your virtual visit to the Aerostar factory! Let's begin our tour!
HTMLText_A32B904C_8032_831C_41D4_804984732A60_mobile.html =
Aerostructeres and Subansamblies Facility


Let's go to the aerostructure and subassembly facility where simple and complex sheet metal parts are made for civil aircraft or even space launch vehicles.


Millions of parts have been delivered from this factory to our customers Airbus, Boeing, Bombardier and others.
HTMLText_A3468C82_8035_8304_41B2_A75E31C637DE_mobile.html =
Civil Aviation Maintenance Hangars


Here we are, in one of the 3 hangars where maintenance is performed for Airbus A320 ceo and neo family and Boeing B737 all series, including MAX - 7/8/9.


In these hangars we perform complex structural repairs, cabin reconfigurations and restorations, structural and avionics modifications and maintenance of composite elements.


In each hangar we can carry out simultaneous activities on 3/4 aircraft.
HTMLText_A3711511_8035_8D04_41D0_57624FB55724_mobile.html =
Electronic Systems Facility


The team in the Integrated Electronic Systems department develops and manufactures power supply systems, antenna rotation systems, interface blocks, central processing units for command/control, merging and unified data display.


Moreover, our colleagues provide integrated logistic services for command control, radar and electronic combat systems, from D-level repairs to test benches and complex system integration stations.
HTMLText_A30F9644_8032_8F0C_41DB_6FD466C0BDBC_mobile.html =
Hydraulic System and Landing Gear Facility


The first stop on our tour is the Landing Gear and Hydraulic Systems Facility.


This is where the flap actuator cylinders, main and nose leg release cylinders, landing gears and actuators are manufactured, as well as various kits of parts used on aircraft such as Airbus A320/A321, A330, A350, Daher TBM 960, Boeing 787 or Super Puma helicopters.


The parts are made of various types of materials such as hard aluminium, steel, stainless steel, high strength steel, bronze, titanium. begin our tour!
HTMLText_A3381F92_8032_7D04_41A4_7F85035C917B_mobile.html =
Non Destructive Testing Line


No defect can pass through!


Non-destructive liquid penetrant testing methods are used to identify hidden cracks, porosity and part integrity throughout the manufacturing flow.


The non-destructive process line is designed for testing with 2 fluorescent penetrant liquids and is equipped with a wash station, a drying oven and a part loading and unloading area.
HTMLText_A3361E8B_8032_7F04_41D0_35A07470F3DA_mobile.html =
Special Processes


Corrosion protection is provided by surface coatings. In Aerostar, we use state-of-the-art processes that replace the hexavalent chromium from classic anodizing with sulphuric and tartaric acid anodizing.


After anodizing, the parts are coated with a thin layer of primer and painted with water-based paints.


Drying in the oven at 80 degrees Celsius for about 25 minutes causes the paint layer to polymerise and thus improves the durability of the part and creates a beautiful finish.


Let's not forget quality inspection, a process whereby our colleagues check each part carefully to spot any imperfections.
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