Aerospace sheet metal fabrication is the highest-specification segment of the sheet metal industry. Safety-critical application, regulatory oversight, traceability requirements and dimensional precision make aerospace sheet metal fabrication supplier qualification significantly more demanding than standard commercial work. This guide covers what makes aerospace different, what certifications to verify, required documentation — and a transparent statement of what Manufyn can and cannot supply in aerospace today.
Discuss your aerospace sheet metal fabrication requirements with Manufyn’s engineers — we advise on feasibility, certification scope and qualification pathway
What Makes Aerospace Sheet Metal Fabrication Different? (AEO Answer)
Aerospace sheet metal fabrication differs from standard fabrication in four ways: (1) full material traceability to mill certificate and heat number on every part; (2) mandatory FAIR to AS9102 format, reviewed by the OEM’s quality team; (3) AS9100D or NADCAP certification for specific processes — ISO 9001 alone is insufficient for Tier 1 aerospace sheet metal fabrication supply; (4) dimensional tolerances to ISO 2768-f or tighter with 100% CMM inspection. For full tolerance data, see our sheet metal fabrication tolerances guide.
Certification Requirements for Aerospace Sheet Metal Fabrication
| Certification | What It Covers | Required For |
|---|---|---|
| ISO 9001:2015 | General QMS — baseline requirement | All aerospace supply; not sufficient alone for Tier 1 |
| AS9100D | Aerospace QMS — adds risk management, FOD prevention, product realisation, AS9102 FAIR to ISO 9001 | Tier 1 aerospace supply; most Tier 2 structural |
| NADCAP | Process-specific: welding, NDT, heat treatment, coatings | Where specific processes are NADCAP-mandated by prime contractor |
| EASA Part 21 POA | Production Organisation Approval | Airworthiness-controlled production parts |
Manufyn current certification: ISO 9001:2015 certified. AS9100D qualification in progress. Aerospace supply available today: non-flight-critical sheet metal (interior fittings, GSE, MRO tooling) at ISO 9001 level. Structural Tier 2+ with full PPAP Level 3/FAIR available. Contact us to discuss your specific application.
Material Traceability for Aerospace Sheet Metal Fabrication
- Mill test certificate (MTC): chemical composition, mechanical properties, heat number, compliance with AMS/ASTM/EN specification
- Heat/lot number: documented on job card, FAIR and shipping documentation
- Certificate of Conformance (CoC): Manufyn signs CoC confirming material used matches MTC and drawing specification
- Cut piece traceability: for primary structure, traceability extends to which specific sheet from the coil was used for which specific part
For standard aerospace sheet metal fabrication material grades and properties, see our sheet metal materials guide
Aerospace FAIR vs Commercial FAIR
| FAIR Section | Commercial FAIR (Manufyn standard) | Aerospace FAIR (AS9102) |
|---|---|---|
| Part ID | Part number, revision | Part number, revision, drawing level, configuration index |
| Material cert | MTC reference | MTC, chemical analysis, heat number, CoC from distributor |
| Dimensional results | All toleranced dims | All drawing dims with balloon-referenced measurement plan; CMM report |
| Process certification | Not required | Records of all special processes with cert references |
| Functional test | Not typically required | Required where drawing calls out functional test |
| Signoff | Inspector sign-off | Quality engineer + responsible individual; AS9102 Form 1/2/3 |
For commercial FAIR documentation, see our prototype sheet metal fabrication guide
Tolerances for Aerospace Sheet Metal Fabrication
Aerospace sheet metal fabrication structural parts typically require ISO 2768-f (fine) as the general tolerance. For the full fine-grade tolerance table, see our ISO 2768 tolerances guide. Key aerospace-specific requirements:
- Hole position: ±0.05mm or better — CMM verified
- Bend angle: ±0.1° for assembly-critical angles — CMM or precision angle gauge
- Flatness: ±0.2mm/300mm for structural skins — surface plate or CMM
- Edge condition: no sharp edges; all edges chamfered or deburred per drawing note
- Surface roughness: Ra 3.2 µm maximum for structural; Ra 0.8 µm for bearing surfaces
Manufyn Aerospace Sheet Metal Fabrication Capability — Transparent Statement
| Application | Manufyn Capability | Certification | Notes |
|---|---|---|---|
| Aircraft interior fittings (non-structural) | Yes | ISO 9001 | Non-flight-critical brackets, panels, storage fittings |
| Ground support equipment (GSE) | Yes | ISO 9001 | GSE fabrication, maintenance tooling |
| MRO tooling and fixtures | Yes | ISO 9001 | Jigs, fixtures, maintenance tooling |
| Structural brackets (Tier 2+) | Yes with PPAP Level 3 | ISO 9001; AS9100D in progress | Customer qualification required; FAIR standard |
| Flight-critical primary structure | Not currently | AS9100D required | AS9100D qualification in progress |
| NADCAP welding | Via NADCAP sub-contractor | Documented subcontract | On request for qualifying projects |
Frequently Asked Questions — Aerospace Sheet Metal Fabrication
Tier 1 aerospace sheet metal fabrication requires AS9100D. ISO 9001 is the baseline — necessary but insufficient for primary structure. Specific processes may additionally require NADCAP accreditation. Manufyn is ISO 9001 certified; AS9100D qualification is in progress. Contact us to discuss your specific requirements.
Aerospace sheet metal fabrication primarily uses aluminium alloys (6061-T6, 2024-T3, 7075-T6), stainless steel 304/316 and 17-4PH, and titanium Grade 2 and 5 (Ti-6Al-4V). All materials sourced with mill test certificates to AMS or ASTM standards. See our sheet metal materials guide for full property data.
Yes — for non-flight-critical and MRO/GSE aerospace sheet metal fabrication at ISO 9001 level, and for structural Tier 2+ with full PPAP Level 3/FAIR. For primary structure requiring AS9100D, Manufyn is in the qualification process. Contact our engineers to discuss your application.
Aerospace sheet metal fabrication structural parts require ISO 2768-f (fine) as the general tolerance — ±0.05mm for dimensions up to 30mm, ±0.1° angular. For the full precision vs standard sheet metal fabrication comparison, including when precision is required and what it costs, see our dedicated guide.
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