Here are a few pictures of the raw plug cutting process before surface finish.

Plates of milling material are aligned on our fast processing router, vacuum clamped and cut in slices that will be glued together at a later stage.



Here is an example showing the female plug wing mold. The hollow shape allows for a reduction of material cost, mold weight and cutting time of about 30%.

For the flying surfaces, we process negative molds to make a composite positive plug. This allows us to work safely on thin trailing edges without braking them, as we have an extensive surface work going on with these parts.





Here are the negative molds completely cut out of the Kuka robot.



Another shot of the male fuselage plug shape being milled on the Kuka. These are the half beaver tail parts. These specific parts are milled from two faces. The negative exhaust radius has too much angle for the water cooled 30 KW exo bearing milling monster head to do its job in one setting without collisions.



We have two Kuka milling robots at the factory. One two ton KR240 on a fixed base and one 4 ton KR320 on a 30 meter long rail. We exclusively use the KR240 at Enata Aerospace as it allows a milling precision of 1/15 mm within a half sphere of 3 meters diameter.