Advancing UK Aerospace, Defence, Security & Space Solutions Worldwide

Aerospace Defence Security

JJ Churchill reduces machining ops by half

Aerospace engineering firm JJ Churchill today announced that it has reduced its tooling costs by 5% with a 50% reduction in the number of machining operations on a specific critical part, achieved with Blue Photon technology which is marketed in the UK and Europe by NCMT Limited.

This technology is applied to a titanium aluminide aerofoil blade component which is an extremely difficult material to fixture and machine. Blue Photon fixes the component to the tool with an adhesive, which cured under UV light, is strong enough for the most rigorous machining techniques including 5?axis CNC. The process is a replacement for encapsulation, providing reduced fixture complexity.

Advertisement
ODU RT

Each machining operation can need its own fixturing, so any reduction in the number of operations will have a huge impact on the efficiency of the process. The reduction in machining operations are achieved by fixing onto a single face of the component, as opposed to potentially many-faced attachments.

Locating on a single face provides access to other faces, enabling several complex features to be machined at the same time. This delivers greater precision during machining, with much tighter tolerances achievable between features. It ultimately reduces the amount of metal wasted/ scrapped, providing resulting benefits.

Once the blade root and tip have been machined held using the Blue Photon technology, the workpiece is transferred to a Starrag five?axis machining centre ? in this case a 28 kW/18,000 revs/min LX051. The workpiece is held in specifically?developed fixturing for the fast and effective complete machining of the aerofoil from forged blanks that are, at most, 5 mm oversize.

The impact on JJ Churchill’s overall production is to increase capacity which is essential as the company continues its high growth trajectory, while also benefitting the environment, another of JJ Churchill’s key performance measures. Using Blue Photon reduces the energy (electricity) required for the process. The current encapsulation method requires a molten metal case being applied to the part to aid holding, a process which requires significant energy to heat the encapsulation material to a sufficient temperature.  In comparison, Blue Photon uses a 12V low?power UV curing box.

Advertisement
Teledyne

Mark Cooper, JJ Churchill’s Managing Director, said: “Blue Photon has substantially increased the capacity and accuracy of our machining operations. We have always manufactured the highest quality components. Now we can do it more quickly and more precisely than before. We will build on this by continuing to invest in the latest technology and apply it to the benefit of our aerospace and power generation customers around the world.”

Adrian Maughan, NCMT Engineering Director, said: “Blue Photon technology enables engineers to realise benefits not possible previously with mechanical fixtures alone.  JJ Churchill have utilised the Blue Photon technology in a very innovative way to deliver productivity benefits for their customers.”

Based in Market Bosworth, Leicestershire, JJ Churchill employs 140 people, and manufactures high precision gas turbine components for the aerospace industry as well as high horsepower diesel engine components and assemblies for industrial and power generation applications. The company is focused on solving ‘sticky niches’ which require a high degree of technical and organisational skill to resolve. It works in areas which require highly skilled engineering in difficult geometries, difficult dimensions and challenging materials.

Advertisement
Babcock LB
UK signs historic trade deal with India

Aerospace Defence Security Space

UK signs historic trade deal with India

24 July 2025

Today, the Prime Minister has welcomed nearly £6 billion in new investment and export wins, set to create over 2,200 British jobs across the country as Indian firms expand their operations in the UK and British companies secure new business opportunities in India, following the signing of an historic UK-India trade deal.

Avolon orders 90 Airbus aircraft

Aerospace

Avolon orders 90 Airbus aircraft

24 July 2025

Avolon has announced an order with Airbus for 75 A321neo aircraft and 15 A330neo aircraft, which are scheduled to be delivered out to 2033.

Heathrow shared apprenticeship scheme set to grow

Aerospace

Heathrow shared apprenticeship scheme set to grow

22 July 2025

Heathrow has pledged to have 500 local apprentices through its shared apprenticeship scheme by 2030 as part of its promise to help neighbours tap into the world of work on their doorstep.

BAE Systems to support Italian airborne electronic attack capabilities

Aerospace Defence

BAE Systems to support Italian airborne electronic attack capabilities

22 July 2025

BAE Systems will support the modification of two aircraft into airborne electronic attack platforms for the Italian Air Force.

Advertisement
Gulfstream RT
UK Government invests £63m to advance SAF production

Aerospace

UK Government invests £63m to advance SAF production

22 July 2025

Passengers are a step closer to greener flights as the UK Aviation Minister Mike Kane today announced the 17 UK companies who will share £63 million to accelerate sustainable aviation fuel (SAF) production.

Zelim’s SWIFT optimises airport rescue ops

Aerospace Security

Zelim’s SWIFT optimises airport rescue ops

21 July 2025

In a development that bolsters its emergency response and rescue capabilities in the event of a ditched aircraft, a major airport in Southeast Asia has installed Edinburgh based Zelim’s SWIFT Rapid Man Overboard Rescue Conveyor aboard its new fast maritime rescue and recovery vessels.

Advertisement
Gulfstream RT