Development, manufacturing and repair of aircraft structures and complete aircraft for civil and military aviation.
Kaelin Aero Technologies GmbH
Oberndorf-Hochmössingen (DE) · Sempach Station (CH) · Bioggio/Lugano (CH)New on Amplifa
Partner for Aircraft Structural Manufacturing and Component Production
Kaelin Aero Technologies GmbH is an aviation company headquartered in Oberndorf-Hochmössingen, specialised in civil and military aircraft structural manufacturing as well as the development and construction of complete aircraft. The company is an EASA Part 21/G production organisation and manufactures individual parts and assemblies from aluminium and steel – among other things as a long-standing supplier to Pilatus Flugzeugwerke AG with around 330 components per year, including the horizontal stabiliser, elevator and rudder as well as the passenger and cargo door for the PC-24. The manufacturing depth covers CAD design, 3D scanning and reverse engineering, CNC milling (3- and 5-axis), hydroforming with presses up to 600 t, press braking, certified aviation welding, heat treatment in accordance with AMS 2750F, surface treatment, tooling and fixture construction as well as structural assembly. In addition to component manufacturing, Kaelin carries out structural repairs and restorations worldwide – from field repairs in Indonesia to structural work on 22 F-5 Tigers in the US Navy's ARTEMIS project. Special focuses include the replica construction of historic aircraft such as the Junkers F 13 as well as the development of own aircraft models (Junkers A50 Junior, A60, B-100C) and modifications such as the Eye-in-the-Sky kit for AS350/H125 helicopters.
- Site
- Oberndorf-Hochmössingen
- Processes
- Design & Development (CAD design, 3D models, modifications, reverse engineering), 3D Scanning / Measurement, 3-Axis Milling (Gantry Milling Machines), 5-Axis Integral Milling (Hermle C22), Hydroforming (Hydroforming/Presses), Press Braking, Heat Treatment (Solution Annealing Aluminium, Stress-Relief Annealing Steel), Painting
- Materials
- Aluminium, Steel, Carbon Fibre (Fibre Composite), Metal (All-Metal Aircraft Construction), TIG Welding (ISO 4063)
- Certificates
- EASA Part 21/G Production Organisation, EN9100-Compliant Quality System, EASA Part 21/G, EN 9100-compliant
- Founded
- 2012
- Industries
- Aviation industry (civil and military), Aircraft manufacturing, Helicopters
- 01
Design & Development (CAD, 3D Scanning, Reverse Engineering)
- 02
Tooling and Fixture Construction
- 03
Single Piece Production (Milling, Forming, Welding)
- 04
Heat Treatment
- 05
Surface Treatment
- 06
Non-Destructive Testing
- 07
Structural Assembly
- 08
Documentation and Shipping
Materials and Aviation-Specific Processes
Aluminium
Main material for aircraft structures; milling, hydroforming, press braking, solution annealing, SurTec 650.
Steel
Milling, press braking, stress-relief annealing and TIG welding (material thickness 1.0–6.4 mm).
Carbon Fibre (Fibre Composite)
Used in the Eye-in-the-Sky lightweight structural element for AS350/H125 helicopters.
TIG Welding (ISO 4063)
Certified according to ISO 24394; material groups A TP1–TP5, B and F TP2/TP3.
Locations
Oberndorf-Hochmössingen
DEHeadquarters, Development & Manufacturing
- Part weight / size
- Milling up to 2050x1550x220 mm; presses 6000x910x820 mm
- Lot size
- Individual parts and assemblies
- Materials
- Aluminium, steel
- 2× 3-axis gantry milling machines (HSC up to 32,000 rpm)
- Hermle C22 5-axis machining centre
- 4× hydraulic presses (hydroforming, max. 600 t)
- Press brake 3 m / 110 t
- Heat treatment furnace AMS 2750F (150–610 °C)
- Paint booth 8x4x2.7 m
- 3D scanner (accuracy down to 0.025 mm)
Sempach Station
CHRepairs & Modifications
Bioggio (Lugano)
CHManufacturing, incl. Eye in the Sky Kit
- Materials
- Carbon fibre
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Design & Development (CAD design, 3D models, modifications, reverse engineering)Engineering | – | – | – | – | – |
| 3D Scanning / MeasurementTesting | Accuracy down to 0.025 mm; volumetric accuracy | – | – | – | – |
| 3-Axis Milling (Gantry Milling Machines)Machining | – | 2050 mm × 1550 mm × 220 mm | – | – | Aluminium, Steel, Plastics |
| 5-Axis Integral Milling (Hermle C22)Machining | – | 450 mm × 600 mm × 330 mm | – | – | Aluminium, Steel |
| Hydroforming (Hydroforming/Presses)Forming | – | 6000 mm × 910 mm × 820 mm | – | – | Aluminium |
| Press BrakingForming | – | 3 m | – | – | Aluminium, Steel |
| Heat Treatment (Solution Annealing Aluminium, Stress-Relief Annealing Steel)Heat Treatment | Temperature range 150-610 °C, tolerance +/- 6 °C | 1300 mm × 2000 mm × 1000 mm | – | – | Aluminium, Steel |
| PaintingSurface | – | 8 m × 4 m × 2.7 m | – | – | – |
| Corrosion Protection Treatment / SurTec 650Surface | – | – | – | – | Aluminium |
| Non-Destructive Testing (Dye Penetrant Testing, Conductivity Testing, Coating Thickness Measurement)Testing | – | – | – | – | Metal |
| Welding (TIG per ISO 4063, certified ISO 24394)Joining | – | – | – | – | Aluminium, Steel |
| Tooling and Fixture ConstructionEngineering | – | – | – | – | – |
| Structural Assembly (Assembly, Sealing, Painting, Corrosion Protection)Assembly | – | – | – | – | – |
| Single Piece Production (Individual Part and Assembly Manufacturing)Machining | – | – | – | – | Metal, Composites |
| Structural Repairs & RestorationsAssembly | – | – | – | – | Metal, Composites |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 3-Axis Gantry Milling Machine | – | 2 | 2050x1550x220 mm; HSC up to 32000 rpm (9 kW / 15 kW) | – | Oberndorf-Hochmössingen |
| 5-Axis Machining Centre | Hermle C22 | 1 | Travel range 450x600x330 mm; 18,000 rpm, optional high-speed spindle up to 50,000 rpm | – | Oberndorf-Hochmössingen |
| Hydraulic Press (Hydroforming) | – | 4 | Working area 6000x910x820 mm; max. press force 600 t; 2.1 mm/s | – | Oberndorf-Hochmössingen |
| Press Brake | – | 1 | Braking length 3 m, 110 t pressing force | – | Oberndorf-Hochmössingen |
| Heat Treatment Furnace (AMS 2750F, Furnace Class 2) | – | 1 | Interior dimensions 1500x2200x1200 mm; calibrated working zone 1300x2000x1000 mm; 150-610 °C | – | Oberndorf-Hochmössingen |
| Paint Booth | – | 1 | 8x4x2.7 m | – | Oberndorf-Hochmössingen |
| 3D Scanner (portable) | – | – | Scan range 0.05-8 m; accuracy down to 0.025 mm | – | – |
Additional services
Reference customers
Quality and Approvals
As an EASA Part 21/G production organisation with an EN9100-compliant quality system, Kaelin manufactures for certified production organisations. Inspection equipment includes 3D scanning, dye penetrant testing, conductivity and coating thickness measurement, eddy current testing as well as X-ray inspection via partners.
| Evidence | Oberndorf-Hochmössingen |
|---|---|
| EASA Part 21/G | |
| EN 9100-compliant |
History
- 2009
Founding of Kaelin Aircraftstructure GmbH (CH); first contract: wing repair on a Super Constellation; start of the Junkers F 13 replica build.
- 2012
Founding of Kaelin Aero Technologies GmbH (DE); construction of Hall 1 for Pilatus PC-6 components.
- 2013
Start of the F 13 replica build with serial number 01 (Anneliese 2).
- 2015
UCL replacement across the entire fleet of the Swiss Air Force; three years of RUAG support in Emmen.
- 2016
Construction of Hall 2; start of production of Pilatus PC-24 components; first flight of the F 13 in Dübendorf.
- 2017
MPVK kit installation on helicopters; start of construction of Hall 3; start of the F 13 small series.
- 2019
Swiss site in Malters; start of construction of Hall 4; build-up of detailed manufacturing with milling machines.
- 2020
Move into Hall 4.
- 2021
Construction of the fatigue test cell and prototype of the Junkers A50 Junior; successful first flight at the end of 2021.
- 2022
Founding of Junkers Aircraft GmbH; start of A60 development.
- 2023
Structural assembly Pilatus PC-7 MKX; relocation of the Swiss site to Sempach; RUAG support in the US Navy's ARTEMIS project.
- 2024
Development of the Eye-in-the-Sky modification for the AS350.
- 2025
Launch of the site at Lugano Airport.
- 2026
Successful first flight of the B-100C on 26 June.