Aerospace CNC Machining: Solving Production Challenges with CR Onsrud

Name: Sanson Machinery Group
Address: 9800 Harbour Place, Unit 114, Mukilteo, WA, 98275, United States
Telephone: 425-513-8263
Price range: $$

Advanced CNC Solutions for Aerospace Composites, Aluminum, Honeycomb, and Large-Format Manufacturing

Aerospace manufacturers face increasing pressure to produce complex components efficiently while maintaining tight tolerances, consistent quality, and reliable production schedules. From carbon fiber composite structures to aluminum components and precision aerospace tooling, selecting the right CNC machining equipment can make a significant difference in manufacturing performance.

At Sanson Northwest Machinery, we understand that aerospace manufacturers aren’t simply looking for another CNC router. They’re looking for solutions to real production challenges.

As an authorized CR Onsrud CNC machinery dealer, Sanson Northwest Machinery helps manufacturers evaluate industrial CNC routing and machining solutions designed for demanding applications, including aerospace manufacturing, composite processing, aluminum machining, and large-format production.

CNC Machining Challenges Facing Aerospace Manufacturers

Aerospace manufacturing often involves specialized materials, complex part geometries, large workpieces, and demanding quality requirements.

Traditional machining methods or older CNC equipment may create production limitations, particularly when working with large composite structures or components requiring multiple machining operations.

Common challenges include:

Complex component geometries: Aerospace components frequently require multi-axis machining, contouring, trimming, and precision drilling.
Large workpieces: Aircraft structures, composite panels, and manufacturing tools can require extended machining envelopes.
Difficult-to-machine materials: Carbon fiber reinforced polymers (CFRP), fiberglass, aluminum, and honeycomb materials require appropriate cutting tools, machining strategies, and workholding.
Production bottlenecks: Multiple setups, manual handling, and secondary machining operations can increase production time.
Consistency and repeatability: Aerospace suppliers must maintain controlled manufacturing processes to satisfy customer specifications and quality requirements.

Choosing a CNC machine based on the application, rather than machine specifications alone, helps manufacturers identify equipment suited to their production requirements.

1. CNC Machining for Carbon Fiber and Aerospace Composites

Carbon fiber reinforced polymers and other advanced composite materials are widely used in aerospace manufacturing because of their strength-to-weight characteristics.

However, machining these materials introduces challenges that differ from conventional metalworking.

Composite machining can involve fiber fraying, delamination, abrasive tool wear, and airborne dust. Proper tooling, cutting parameters, workholding, and dust extraction are essential.

CR Onsrud industrial CNC machining solutions can be configured for applications such as:

Carbon fiber component trimming
Fiberglass panel routing
Composite drilling and contouring
Aerospace interior component manufacturing
Composite mold and tooling production
Large composite structure processing

For manufacturers working with complex composite geometries, 5-axis CNC machining can provide additional flexibility by allowing cutting tools to approach components from multiple orientations.

This can reduce the need for repositioning and additional setups, depending on the part geometry and machine configuration.

Why This Matters

Aerospace composite manufacturers should evaluate CNC equipment based on material requirements, component size, machining complexity, dust management, and production volume.

CR Onsrud offers CNC machining platforms designed to address these types of industrial applications.

2. Large-Format CNC Machining for Aerospace Structures

Not every aerospace component fits within a conventional CNC machining center.

Manufacturers producing large panels, structural components, molds, fixtures, or aerospace tooling may require equipment with extended travel and larger work envelopes.

CR Onsrud’s G-Series CNC machining platforms offer moving-gantry configurations designed for large-format industrial machining.

Depending on the model and configuration, G-Series machines are available with extended table lengths, multiple spindle options, and 3-axis or 5-axis machining capabilities.

These machines can be evaluated for applications including:

Large aerospace composite panels
Aircraft structural components
Aerospace molds and patterns
Large manufacturing fixtures
Carbon fiber trimming operations
Complex industrial tooling

The Advantage of Large-Format Machining

A properly configured large-format CNC machine may allow manufacturers to process components that would otherwise require multiple setups or alternative manufacturing methods.

Reducing unnecessary handling and repositioning can help improve workflow efficiency and production consistency.

For aerospace suppliers considering larger components or additional manufacturing capacity, the available machining envelope should be a major consideration during equipment selection.

3. CNC Machining Solutions for Aerospace Aluminum Components

Aluminum remains an important material in aerospace manufacturing because of its machinability, strength-to-weight properties, and availability in specialized alloys.

Manufacturers working with aluminum components may require high spindle performance, rigid machine construction, effective chip management, and reliable workholding.

CR Onsrud offers industrial CNC machining equipment capable of processing aluminum and other nonferrous materials when appropriately configured.

Potential applications include:

Aluminum aerospace components
Aircraft interior structures
Aluminum plate machining
Manufacturing fixtures and tooling
Aluminum extrusion processing
Large-format aluminum components

Selecting the Right Machine for Aluminum

Not all CNC routers are equally suited to aluminum machining.

The appropriate machine depends on material grade, cutting forces, required tolerances, part geometry, workholding, and production volume.

Sanson Northwest Machinery can work with manufacturers and CR Onsrud to evaluate whether a CNC routing platform is appropriate for their aluminum machining requirements.

4. Aerospace Honeycomb Core Processing

Honeycomb materials are commonly used in aerospace sandwich structures where lightweight construction and structural performance are important.

Machining honeycomb cores requires specialized cutting and handling techniques to maintain dimensional accuracy and protect delicate material structures.

CR Onsrud offers a dedicated 5-axis Honeycomb Processing Cell designed to combine high-speed cutting and CNC machining operations.

The system incorporates an integrated bandsaw to support honeycomb cutting and machining within a specialized manufacturing platform.

Potential applications include:

Aerospace honeycomb core processing
Aircraft interior panels
Lightweight structural components
Contoured honeycomb materials
Specialized composite manufacturing

For manufacturers processing significant volumes of honeycomb material, dedicated equipment may provide advantages over general-purpose machining methods.

5. When Should Aerospace Manufacturers Consider 5-Axis CNC Machining?

Five-axis CNC machining provides additional tool orientation capabilities compared with conventional 3-axis machining.

For aerospace applications, this can be particularly valuable when components feature complex contours, angled surfaces, or multiple machining orientations.

Potential advantages of 5-axis CNC machining include:

Access to complex part geometries
Reduced repositioning for certain components
Improved flexibility for trimming and contouring
Machining of angled features
Potential reductions in secondary operations
Greater flexibility for complex aerospace tooling

However, 5-axis machining is not automatically the best solution for every application.

Manufacturers processing primarily flat panels or simpler components may find that a properly configured 3-axis CNC router provides the capabilities they need.

The correct decision depends on the parts being manufactured, required accuracy, production volume, and overall machining process.

6. Choosing CNC Equipment Based on Your Aerospace Application

Before investing in a new CNC machining system, manufacturers should evaluate their current and future production requirements.

Important considerations include:

Material Type: Are you machining carbon fiber, fiberglass, aluminum, honeycomb, tooling board, or multiple materials?

Part Dimensions: What is the maximum component size, and what machining envelope will be required?

Part Geometry: Can components be machined using 3-axis equipment, or would 5-axis capability provide meaningful advantages?

Production Volume: Are you manufacturing prototypes, short production runs, or high-volume components?

Workholding Requirements: Will your application require vacuum fixturing, mechanical clamping, or specialized tooling?

Quality Requirements: What tolerances, surface finish requirements, and inspection procedures must be maintained?

Future Expansion: Will your operation require additional capacity or more complex machining capabilities in the coming years?

Evaluating these factors helps manufacturers select equipment based on actual production needs rather than purchasing unnecessary capabilities.

7. Why Work with Sanson Northwest Machinery for CR Onsrud Equipment?

Sanson Northwest Machinery, located in Mukilteo, Washington, is an authorized CR Onsrud machinery dealer serving industrial manufacturers in the Pacific Northwest.

We help customers explore CNC equipment solutions for aerospace, composites, metalworking, woodworking, and other industrial manufacturing applications.

Our goal is to help manufacturers identify equipment that fits their machining requirements, production objectives, and long-term manufacturing plans.

Whether your operation is expanding its aerospace manufacturing capabilities, replacing older CNC equipment, or considering bringing outsourced machining operations in-house, Sanson Northwest Machinery can help you evaluate available CR Onsrud solutions.

Frequently Asked Questions About Aerospace CNC Machining

Can CNC routers machine carbon fiber aerospace components?

Yes. Industrial CNC routers designed and properly configured for composite machining can trim, drill, and contour carbon fiber components. Appropriate tooling, dust extraction, cutting parameters, and workholding are essential.

Can CR Onsrud CNC machines process aluminum?

Yes. CR Onsrud offers industrial CNC machining equipment for aluminum applications. Machine selection and configuration should be based on the material, component geometry, tolerances, and required production performance.

Is 5-axis CNC machining necessary for aerospace manufacturing?

Not always. Five-axis machining is particularly useful for complex geometries and multi-orientation machining, while 3-axis equipment may be appropriate for simpler components and flat-panel applications.

What CNC machines are suitable for large aerospace composite components?

Large-format moving-gantry CNC machines, including appropriately configured CR Onsrud G-Series systems, can be considered for large aerospace components, composite structures, and tooling applications.

Where can aerospace manufacturers purchase CR Onsrud CNC machinery in Washington?

Sanson Northwest Machinery is an authorized CR Onsrud dealer located in Mukilteo, Washington. The company assists manufacturers with CNC equipment selection and machinery inquiries throughout its service territory.

Expand Your Aerospace Manufacturing Capabilities with CR Onsrud

The right CNC machining solution starts with understanding your application.

Whether you’re machining carbon fiber, aluminum, honeycomb, aerospace tooling, or large structural components, Sanson Northwest Machinery can help you explore CR Onsrud equipment suited to your manufacturing requirements.

Contact Sanson Northwest Machinery to discuss your aerospace CNC machining application.

Sanson Northwest Machinery
9800 Harbour Place, Unit 114
Mukilteo, WA 98275

Phone: 425-513-8263
Email: sales@sansonmachinery.com

Learn more about CR Onsrud CNC Routers:
https://www.sansonmachinery.com/c-r-onsrud/

Explore CR Onsrud Aerospace Applications:
https://www.sansonmachinery.com/c-r-onsrud/applications/aerospace/

Sanson 2510 Hardware Insertion Press:

A Smart Alternative for Fastener Installation

When manufacturers look for a hardware insertion press, two names have traditionally come up again and again: Haeger and PEMSERTER. But today, fabricators have another option—one designed around the features shops actually need, without unnecessarily complicating the machine or the investment.

Meet the Sanson 2510 Hardware Insertion Press, available in both 2510M Manual and 2510A Automatic configurations.

At Sanson Machinery, hardware insertion isn’t a new market for us. The Eugene T. Sanson Company was the first distributor of the Haeger press and helped introduce hardware insertion technology to manufacturers throughout the United States. Over the years, the Sanson companies sold well over 1,000 Haeger machines. That experience gave us decades of firsthand knowledge about what customers expect from an insertion press.

The Sanson Inserter was developed with that experience in mind: a simple, reliable and cost-effective hydraulic hardware insertion machine.

Why Consider the Sanson 2510?

The 2510 is built for manufacturers that need serious insertion capability without paying for complexity they may not need.

With 10 tons of pressing capacity and a 25-inch throat, the Sanson 2510 provides the force and workpiece accessibility required for a wide range of sheet metal fabrication applications.

It is designed for installing common self-clinching and captive hardware, including:

Nuts
Studs
Standoffs
Captive fasteners
Threaded inserts
Other press-in hardware used throughout sheet metal fabrication

Whether you’re producing electrical enclosures, aerospace components, HVAC equipment, cabinets, electronics, industrial equipment or general fabricated sheet metal products, the 2510 gives your operators a dedicated machine for consistent hardware installation.

2510M: Keep Hardware Insertion Simple

Not every shop needs an automated insertion system.

For job shops, lower-volume production environments and manufacturers that frequently change between different hardware, the Sanson 2510M Manual Hardware Insertion Press provides a straightforward solution.

Instead of investing in automation that may not be necessary for the application, the 2510M gives manufacturers the pressing capability of the 2510 platform in a simple manual configuration.

This makes the 2510M especially attractive for shops where flexibility matters more than producing thousands of identical parts.

Load the hardware. Position the part. Insert the fastener. Move on to the next job.

For many fabrication shops, that’s exactly what they need.

2510A: Increase Production with Automatic Feeding

When hardware volume increases, manually handling every fastener can become a production bottleneck.

That’s where the Sanson 2510A Automatic Hardware Insertion Press comes in.

The 2510A combines the 10-ton, 25-inch-throat 2510 platform with automatic fastener feeding capability. Instead of the operator manually loading each individual piece of hardware, the feeding system delivers hardware into position for installation.

For repetitive production, that can significantly improve the workflow around the insertion operation.

The operator can spend more time handling the workpiece and less time picking up and positioning individual fasteners.

For manufacturers running larger batches of parts containing the same hardware, the difference between manual and automatic feeding can add up quickly over an entire shift.

An Alternative to Haeger and PEMSERTER

Haeger and PEMSERTER have been established names in hardware insertion for decades, and both offer capable equipment.

The question for a buyer shouldn’t simply be:

“What brand have we always purchased?”

A better question is:

“What machine gives our shop the capability we actually need at the right investment?”

For many manufacturers, that answer may be the Sanson 2510.

Current Haeger 824 machines, for example, are built around an 8-ton/24-inch platform, while the Sanson 2510 provides 10 tons of pressing capacity with a 25-inch throat. Haeger also offers sophisticated controls and automation options that can be valuable in the right production environment—but not every manufacturer requires that level of technology.

The Sanson approach is different.

We wanted to offer customers a straightforward hydraulic insertion press with the capacity, accessibility and productivity needed for everyday manufacturing—at a competitive price point.

If your application doesn’t require every available automation feature, why pay for equipment based around features you may never use?

And if production does justify automatic feeding, the 2510A gives you that option.

Manual or Automatic? Choose the Machine Around Your Production

That’s one of the advantages of the Sanson 2510 platform.

Choose the 2510M when your operation involves shorter runs, frequent hardware changes, prototype work, job-shop production or applications where manual hardware loading makes sense.

Choose the 2510A when you’re installing larger quantities of the same hardware and want automatic feeding to help increase throughput and reduce repetitive manual handling.

You aren’t forced into one style of production.

You choose the machine that fits the work going through your shop.

Backed by Sanson’s Hardware Insertion Experience

There’s another important difference when purchasing a Sanson Inserter:

You’re buying it from a company that has been involved with hardware insertion equipment since the technology’s early days.

Sanson didn’t enter this market yesterday.

Our history goes back to the original introduction of Haeger hardware insertion presses. The Eugene T. Sanson Company helped pioneer the sale of these machines throughout the United States, and the Sanson companies ultimately sold more than 1,000 Haeger insertion presses.

That experience matters.

We’ve worked with manufacturers using insertion equipment for decades. We understand the machines, the tooling, the applications and the questions that come up when deciding how to install hardware efficiently.

The Sanson 2510 is the next chapter in that history.

Don’t Buy a Name. Buy the Machine That Fits Your Application.

If you’re considering a new hardware insertion press, compare your options.

Look at Haeger.

Look at PEMSERTER.

Then look at the Sanson 2510.

Compare the pressing capacity. Compare the throat depth. Compare the configuration. Compare the features your operators will actually use.

And most importantly, compare the investment.

You may find that you don’t need to spend more to get the hardware insertion capability your shop requires.

Sanson 2510M & 2510A Hardware Insertion Presses

10-Ton Pressing Capacity | 25-Inch Throat | Manual & Automatic Models Available

Sanson Machinery has both manual and automatic hardware insertion machines available. Contact our team to discuss your fasteners, production requirements and application, and we’ll help determine whether the 2510M or 2510A is the better fit for your operation.

Sanson Northwest / Sanson Machinery Group
Mukilteo, Washington
425-513-8263
Sales@sansonmachinery.com

Hardware insertion doesn’t have to be complicated—or overpriced. Ask us about the Sanson 2510.

Request a Quote Today

HYDMECH Band Saws: Built for the Demands of Pacific Northwest Manufacturing

From structural steel and aerospace to marine fabrication, machine shops, and general manufacturing, the Pacific Northwest has a diverse metalworking industry. No matter the application, one thing remains consistent: accurate and efficient material cutting is where production begins.

For manufacturers looking to improve that first step, HYDMECH band saws have earned a strong reputation for performance, durability, and automation.

At Sanson Northwest, we represent HYDMECH throughout the Pacific Northwest and work directly with customers to help determine which saw best fits their material, production requirements, and long-term goals.

Who Is HYDMECH?

HYDMECH is a North American manufacturer specializing in metal-cutting band saws and cold saws. The company has been building sawing equipment for decades and today offers one of the industry’s broadest selections of metal-cutting saws.

Their equipment ranges from smaller manual machines for job shops and maintenance departments to large automatic production saws designed to process material continuously.

HYDMECH’s product lineup includes:

Horizontal band saws
Vertical band saws
Mitering band saws
Automatic production saws
Double-column band saws
High-production carbide saws
Cold saws

This variety is important because the right saw isn’t simply determined by the largest piece of material you need to cut.

Material type, bundle size, production volume, required cut accuracy, miter requirements, blade life, operator involvement, and future growth all play a role.

Why HYDMECH Fits the Pacific Northwest

The Pacific Northwest has a unique manufacturing base.

Across Washington, Oregon, Idaho, and the surrounding region, we work with companies involved in industries such as:

Structural steel fabrication
Aerospace and defense
Marine and shipbuilding
General metal fabrication
Machine shops
Equipment manufacturing
Transportation
Construction and infrastructure
Agricultural and industrial equipment

These businesses may be cutting everything from small tubing and aluminum extrusion to large structural shapes and solid material.

That variety makes flexibility extremely important.

A fabrication shop processing structural steel may need the ability to quickly miter large beams, while a production facility cutting hundreds of identical parts may care more about automation, repeatability, and reducing operator involvement.

HYDMECH offers equipment for both environments.

Manual, Semi-Automatic, or Fully Automatic?

One of the first decisions when selecting a band saw is determining how much automation makes sense.

Manual Saws

Manual saws can be an excellent fit for maintenance departments, smaller fabrication shops, and facilities that don’t require continuous production cutting.

They provide a straightforward and economical solution when an operator is already available to handle material positioning and machine operation.

Semi-Automatic Saws

Semi-automatic saws reduce operator involvement while maintaining flexibility.

These machines are particularly useful for job shops where material sizes and cut lengths frequently change. The operator positions the material, while the machine automates portions of the cutting cycle.

For many Pacific Northwest fabrication shops, this can provide a strong balance between productivity, versatility, and investment cost.

Automatic Saws

When a company is repeatedly cutting material to length, automation can dramatically change productivity.

Automatic HYDMECH saws can feed material, position it, clamp it, complete the cut, and continue through programmed quantities.

Instead of having an employee continually measuring and repositioning stock, the operator can load the machine, enter the job parameters, and allow the saw to process the material.

For higher-volume operations, that reduction in operator involvement can be just as important as the cutting speed itself.

Mitering Saws for Fabrication

For structural and general fabrication shops, mitering capability can be extremely valuable.

Many HYDMECH models are designed specifically around this type of work.

Rather than repositioning long or heavy material to create an angled cut, the saw head can rotate to the required angle.

This can be particularly useful when processing:

Structural tubing
Pipe
Angle
Channel
I-beam
Rectangular tubing
Other structural profiles

When handling 20- or 40-foot lengths of steel, reducing unnecessary material movement can make a noticeable difference in both productivity and material handling.

The HYDMECH S-Series

One of HYDMECH’s most recognizable product families is its S-Series of horizontal pivot band saws.

These machines are commonly found in fabrication and metalworking environments because they combine relatively compact footprints with substantial cutting capacity.

Depending on the model, S-Series machines are available with different capacities, automation levels, and options.

At Sanson Northwest, the HYDMECH S-20A is one example of the type of saw we see fitting a wide range of regional applications.

The S-20A combines automatic operation with the versatility required by many fabrication and production environments. For a shop that has outgrown manual material feeding but still needs flexibility, this type of machine can represent a significant step forward in productivity.

Looking Beyond Cutting Capacity

When comparing band saws, it’s easy to focus almost entirely on maximum capacity.

If you need to cut 12-inch material, for example, it might seem logical to simply purchase a saw capable of cutting 12 inches.

But capacity is only part of the equation.

We also look at questions such as:

What material are you cutting?

Solid round material behaves differently from rectangular tubing, structural shapes, or bundles.

How many cuts are you making each day?

A shop making 15 cuts per day has very different requirements from one making several hundred.

How frequently do your cut lengths change?

High-mix job shops may prioritize flexibility, while production facilities may benefit more from automation.

Do you need miter capability?

For structural fabrication, this can significantly affect which machine configuration makes sense.

How is material getting to and from the saw?

Conveyors, material handling, forklifts, cranes, and floor space should all be considered.

Where does the operator fit into the process?

Sometimes the biggest productivity improvement isn’t increasing blade speed. It’s reducing the amount of time an employee spends measuring, positioning, clamping, and handling material.

A Saw Is Part of a Cutting System

The saw itself is only one part of an efficient sawing operation.

Depending on the application, a complete system may also include:

Infeed and outfeed conveyors
Material stops
Bundling systems
Mist lubrication
Chip removal
Blade monitoring
Material handling equipment
Automated feeding systems

When these components are properly matched, the result can be a much more efficient material-processing area.

Local Support Matters

Purchasing a band saw isn’t only about selecting a machine from a catalog.

Eventually you’ll need blades, parts, service, troubleshooting, or help determining how to improve a cutting application.

That’s where working with a regional machinery supplier becomes valuable.

Sanson Northwest has been supplying and supporting metal fabrication equipment throughout the Pacific Northwest for decades.

Because we’re located in the region, we understand the types of manufacturers operating here and the applications they encounter.

Our goal isn’t simply to sell the largest saw possible. It’s to understand:

What are you cutting?
How large is it?
How many pieces are you producing?
What problems are you experiencing with your current process?

From there, we can help determine which HYDMECH configuration makes sense.

Is It Time to Upgrade Your Saw?

An older band saw may still make accurate cuts, but that doesn’t necessarily mean it’s keeping up with your operation.

Some signs that it may be time to look at a newer saw include:

Operators spending significant time measuring and feeding material
Increasing production requirements
Difficulty maintaining cut consistency
Excessive blade consumption
Frequent machine repairs
Needing greater cutting capacity
Increased demand for miter cutting
Bottlenecks forming at the saw
Difficulty finding replacement parts for older equipment

In many shops, sawing is one of the first operations material goes through. If the saw becomes a bottleneck, every operation downstream can be affected.

Improving the cutting process can therefore have an impact far beyond the saw itself.

HYDMECH Band Saws from Sanson Northwest

Whether you’re replacing an aging saw, adding capacity, or moving toward automated material processing, HYDMECH offers machines for a wide range of applications.

At Sanson Northwest, we can help evaluate your material sizes, production requirements, floor space, automation needs, and budget to determine which HYDMECH saw makes the most sense for your operation.

We can also help with new and used fabrication machinery, saw blades, tooling, parts, service, and complete equipment solutions for manufacturers throughout the Pacific Northwest.

If you’re considering a new band saw, send us your material specifications and production requirements. We’ll help you determine the right machine for the job.

Sanson Northwest
Mukilteo, Washington
425-513-8263
Sales@sansonmachinery.co

Looking for a HYDMECH Band Saw?

Contact Sanson Northwest to discuss your application, request pricing, or learn more about available HYDMECH machines.

Tell us what you’re cutting, and we’ll help you find the right saw.

Aerospace CNC Machining Solutions: Composites & Aluminum