Ricardo’s AS9100D Aerospace Manufacturing Capability Explained

Worldwide air passenger demand is forecasted to double by 2050 ^[1], while the global military fleet is expected to rise by 13.4% over the next decade, resulting in over 50,700 aircraft by 2036 ^[2]. This rapid growth is driving the world’s leading aerospace OEMs to accelerate the production of both civil and defence aircraft, increasing the need for responsive, reliable suppliers more than ever before.

Tony Golland, Ricardo’s Market Head of Defence and Aerospace, explains how we are supporting our aerospace clients to tackle their supply chain challenges.

Ricardo's Aerospace Manufacturing Capability

‘We are perhaps best known for our motorsport and performance automotive capability, but Ricardo has actually been supplying AS9100D- and ISO 9001-certified components to tier 1 airframers and other aerospace customers for over more like 20 years,’ highlights Tony, ‘We specialise in the production of made-to-specification torque-transmitting components for secondary structural applications.’

Pictured: Tony Golland, Market Head of Aerospace and Defence

 ‘Our precision manufacturing techniques with specialist materials enable us to achieve tight tolerances, predictable quality and reliable consistency within a regulated aerospace environment, enabling us to support the predictable quality and programme stability that our clients require.’

We can supply a wide range of parts to our customers, but we specialise in the manufacture of components with complex geometries, tight tolerances, demanding load paths, and integrated features such as internal and external gear teeth. Typical suites of aerospace parts include output shafts, stub shafts, earth rings, and housing stators, many of which require high levels of precision, concentricity, and surface integrity.

Learn more about our AS9100D Aerospace Manufacturing Capability

Why Ricardo?

‘Our manufacturing capability is rooted in Ricardo’s heritage,’ continues Tony, ‘One of our biggest strengths is the extensive knowledge and skill base within the team. Our aerospace programmes are serviced by a team of highly skilled technicians, manufacturing engineers, and machine programmers – all supported by our in-house Quality Assurance, Supplier Quality, Sub-Contract Management, Customer Liaison and Project Management, and Inspection departments.’

‘Their expertise really shines through when it comes of complex components which are difficult to manufacturer under tightly controlled conditions, while maintaining the documentation, traceability, and process discipline that modern airframers demand.’

Access to cross-sector expertise

Partnering with Ricardo gives our clients access to a suite of strategies specifically developed for the aviation industry, whilst benefiting from our wider cross-sector expertise in other highly regulated markets, such as motorsport.

Ricardo provides engineering and manufacturing services to a variety of markets ranging from top-tier motorsport to the defence applications. This breadth of experience means we can integrate proven technologies and practises from other sectors into aerospace projects, whilst ensuring that components meet customers’ specifications.

While our ability to meet stringent aerospace quality and compliance standards feeds into projects for other sectors, benefiting customers in Motorsport, High Performance, Defence, Marine and Off-Highway.

‘Supplying a blend of markets also allows us to ride the peaks and troughs in demand for each sector,’ explains Tony. ‘This strengthens Ricardo’s stability and resilience as an aerospace component supply as we can retain our workforce and machinery even during periods of global volatility – ensuring that our clients can depend on us to meet programme demand.’

Pictured: Ricardo's CNC experts are supported by the latest technologies

Aerospace-centric Processes and Control

All of our aerospace components go through a rigorously controlled set of processes certified to AS9100D and ISO 9001 – and often exceeding these requirements to ensure repeatable quality and reliability. Multiple in‑process inspections are applied based on part complexity and customer requirements, supported by advanced CNC machining and inspection technologies.

‘Over the years, Ricardo has established an iterative NPI process which onboards a customer’s design and thoroughly defines the production stages necessary to create parts tailored to specific requirements. This underpins all of the aerospace make-to-print work,’ adds Tony, ‘This includes early review of customer drawings and requirements, defined manufacturing routes, identification of critical features, and validation through first article inspection where required. As a result, for a typical 12-to-18-month project, we can deliver premium products that meet customer needs – right first time.’

Stable and Traceable Supply Chain

Reliability of supply is essential for aerospace programmes, and that extends to our supply chain too. 
‘We only use customer-approved raw material suppliers for our aerospace components which are managed within a bonded Stores area to ensure segregation, traceability, and compliance from receipt all the way through to final manufacture,’ explains Tony.

While Ricardo focuses on its specialist aerospace machining capability, selected sub‑contract processes are used where required to support customer delivery schedules. These processes typically include specialist operations such as plating processes, heat treatment, shot peening, nitral etching, and crack detection. These are all performed by established industry specialists who are also accredited for aerospace applications and approved by our customers. Each sub-contracted operation is subject to a FAIR or Delta FAIR.

Tony adds, ‘Ricardo maintains long‑standing relationships with its sub‑contract partners and retains full end‑to‑end ownership of quality, delivery, and compliance for both in‑house and outsourced operations.’

Continued Investment to Boost Capability

Millions of pounds have recently been invested in a suite of new multi-axis machines including a universal grinder, a profile gear grinder and a multi-tasking lathe. Utilising the latest equipment allows more turning, milling and gear cutting operations to be completed without tooling and fixture changeovers, retaining the original datum points and consequently increasing accuracy.

Another addition to Ricardo’s asset portfolio is a novel vacuum furnace with high pressure gas quench heat treatment facility, which is due to come online later this year.  It achieves temperatures of 1,000°C and pressures of 20 bar allowing a more controlled environment to meet specification and minimise distortion. The two heat chambers heat up to working temperature faster than the previous system, improving operational efficiency and costs.  Mention electrically heated reduces cost and better carbon footprint.

A Component Manufacturing Service Engineered for Aerospace

The aviation industry is navigating a turbulent period with the aftermath of the global pandemic followed by ongoing geopolitical conflict and fluctuating fuel prices. Despite this, the underlying demand for air travel is only increasing; driving the need for more aircraft.

‘Aerospace needs resilient manufacturing partners that have the resources available to manage variable forecasts and long lead times whilst delivering high quality, fully certified components,’ concludes Tony, ‘With over a decade of proven capability, we continue to invest in our team and technology to strengthen our ability to support airframers through the imminent surge in aircraft production.’

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References

^[1] 2026. Air Travel Demand Will More Than Double by 2050 [Online]. IATA (International Air Transport Association).

^[2] D.B., I.F., L.H., 2026. Global Military Aircraft Fleet And Sustainment Outlook [Online]. Oliver Wyman.