Military Helicopter

Our Commitment To Manufacturing Aerospace Components

Northstar Aerospace® maintains several NADCAP certified facilities across the continent. These facilities hold multiple manufacturing capabilities, including the production of fabricated and machined components for fixed and rotary-wing aircraft. Our quality control upholds the highest standards of excellence in all respects.

Northstar Aerospace® Quality Policy

Northstar Aerospace® is committed to manufacturing aerospace components and delivering products that meet customer requirements. We build quality and reliability into our products and processes by leveraging best practices and strategic planning. We expect our employees to take ownership and promote a proactive work environment based on team member involvement and problem-solving. Northstar Aerospace® is dedicated to continuous improvement and will work to improve the effectiveness of our quality management system and the quality of products offered.

All Northstar sites are certified and registered to ISO: 9001-2015, SAE AS9100, Rev. D. Each site has appropriate NADCAP certifications applicable to their product lines.

Chicago Facility

This facility is located in Bedford Park, IL, and is the leading independent manufacturer of helicopter transmission components in the United States. It is ISO 9001:2015 and AS 9100 D certified. We are also NADCAP certified in chemical processing, heat treating, and nondestructive testing.

The facility is also Boeing D1-4426-approved for multiple special processes. It offers turn-key services for drive train requirements, including:

  • Design & Manufacturing Engineering
  • Manufacture of Quality Gearing
  • Program Management
  • Heat Treatment
  • Plating
  • NDT Capabilities, Including Magnaflux, Zyglo, and Nital Etch
  • Precision Assembly
  • Dynamic Testing

We are the original and primary manufacturer of aerospace components such as transmission gearing, kits, and drive components for the CH-47 Chinook family of rotorcraft, as well as MRO services on the forward, aft, and combiner transmissions.

Northstar Aerospace® is also the original manufacturer of the AH-64 Apache main transmission. The facility serves as a depot repair station for Apache transmission overhaul.

We also manufacture, assemble, and test the Airframe Mounted Accessory Drive (AMAD) unit for the F-22 Raptor fighter jet and provide repair and overhaul services.

Phoenix Facility

The Phoenix, AZ, facility offers a broad scope of services, including the manufacture of aircraft power systems, structures, and flight control surfaces. We are a highly respected contract manufacturer for the North American aerospace industry. Our facility manufactures complex, fabricated, and machined components for leading engine and aircraft builders and the US military. We also supply fixed and rotary wing aircraft in commercial and military applications.

Our fabricated engine product capabilities include:

  • Hydro Forming
  • Draw, Roll & Brake Forming
  • Laser Fitting & Welding
  • Vacuum Bonding
  • Titanium Inert Chamber Welding
  • Seam, Spot & Overlap Spot
  • CNC TIG Welding
  • TIG Welding

We are certified in ISO 9001:2015 and AS 9100 D

This facility is experienced in the manufacture of aircraft power systems, structures, and flight control surfaces.

We also hold our NADCAP certification for welding (TIG, seam, and spot), chemical processing, and NDT (MT, PT, RT).

Our Phoenix location is Boeing D1-4426 approved for multiple special processes, including machined components:

  • 24 Machining Centers From 3-4-5 Axis CNC Machining Centers Up To 5 Foot Cube
  • 13 CNC Turning Centers With 58 Inch Diameter Capacity
  • Multi-Spindle FMS Application & Eight Single-Spindle Palletized Cells
  • Tooling & Support Shop

Our composite manufacturing includes:

  • Wet Lay-Up & Pre-Preg Applications
  • 10’ x 30’ Autoclave
  • Curing Ovens
  • Hot Bond Table
  • Controlled Environment Lay-Up Room

We also supply organic and inorganic coatings, such as:

  • Painting & Wipe Coats
  • Anodizing for Magnesium
  • Chemical Conversion Coating of Aluminum
Windsor Facility

The Northstar Aerospace® facility in Tecumseh, ON, Canada, is a leading manufacturer of precision gears such as spiral, helical, and spur, in addition to Curvic grinding, shafts, and splines from prototype to high-volume production.

Our Ontario facility is AS9100 D with ISO 9001: 2015 certified.

We are also NADCAP certified for chemical processing and DoT approved.

Our machining capabilities include:

  • CNC Turning
  • CNC Milling
  • CNC Grinding
  • Gear Generating & Grinding
  • Curvic Grinding
  • Hobbing
  • Shaping & Broaching from 1/4 Inch to 24 Inch in Diameter up to 40 Inch Lengths

The facility inspection competencies include:

  • Zeiss® CMM
  • Mitutoyo® CMM
  • M&M® Gear Analyzer
  • Hommel® Optical Measuring Equipment

We are also the sole provider of the IGB (internal) gear package, SAGB (Step Aside) gear package, and angled drive shaft for Rolls-Royce Trent 1000 engines used to power the Boeing 787 Dreamliner aircraft.

Customer & Quality Specifications
  • AgustaWestland QRS01
  • Boeing D1-9000
  • General Electric S1000
  • Hamilton Sundstrand ASQR-01
  • Rolls-Royce RR 9000:SABRe
  • Sikorsky SQAR-100
  • Columbia Helicopters 06-RDE-0116-2
Supplier Quality Requirement Documents

V29 Supplier Quality Purchase Order Clauses Windsor.pdf

F-P-0003 Standard Flow Down Requirements J Chicago.pdf

Terms and Conditions.pdf

NCO-SQ-MAN-0001 Supplier Quality Manual Rev F.pdf

Supplier Nonconforming Product Notification Form

Corrective Action Request Form

16-07-3 Problem Solving Form