Milling the Future of Aerospace
Precision Machines for Aircraft and Space Components
Milling Machines for Aerospace
Take off for new opportunities.
Custom Milling Machine Aerospace Solutions – Precision and Reliability at the Highest Level
In the aerospace industry, components demand the highest level of precision. Minimal tolerances, complex geometries, and a diverse range of materials such as aluminum, titanium, carbon fiber, and other advanced composites place extreme demands on manufacturing processes. Meeting these challenges requires specialized milling machine aerospace solutions.
We not only design highly precise gantry milling machines, but also develop custom clamping systems tailored to each part. From hard tooling for specific components to universal multi-tool clamping setups, our solutions ensure maximum repeatability, stability, and efficiency throughout production.
Our offerings cover the entire process chain: high-performance machining of aluminum and titanium, precision processing of carbon fiber and other composites, as well as hybrid techniques that combine milling with abrasive waterjet or laser cutting. As a provider of turnkey solutions, we deliver everything from planning and machine design to seamless integration into existing production lines.
With our milling machine aerospace solutions, manufacturers achieve unmatched precision, flexibility, and reliability—exactly what is needed for today’s aerospace component production.
PRECISION IN MOTION!
FOOKE Milling Machine Aerospace Solutions for Every Component
Trusted Aerospace Solutions
Our milling machine aerospace technology enables tailored manufacturing processes that consistently deliver top-tier precision, quality, and efficiency for the aviation industry.
Achieving 50 Percent Weight Reduction on a 33 by 7 Foot Fuselage
Fuselage Surface Machining
Reduce Weight, Boost Productivity, Cut Costs: FOOKE Aerospace Milling Machine Solutions
Weight reduction, increased productivity, and cost efficiency are key challenges in the aerospace industry. FOOKE understands your processes and delivers solutions that achieve these goals measurably.
With our high-precision mechanical milling machine aerospace technology, we replace conventional chemical processes, enabling up to 50 % weight reduction on aircraft fuselage skins. At the same time, our turnkey solutions increase productivity by up to 35 %, shorten production cycles, and make your manufacturing more environmentally friendly.
Our expertise helps OEMs and suppliers optimize processes, reduce costs, and produce lighter, more efficient aircraft—without compromising quality or precision.
Experience how FOOKE milling machine aerospace solutions take your production to the next level.
Highly Complex Spherically Shaped Carbon Fiber Components
WING FLAPS
Für die 5-Achs-Bearbeitung, das Bohren und die Kantenbearbeitung von CFK-Werkstücken setzt unser Kunde auf die FOOKE ENDURA® 611LINEAR Portalfräsmaschine. Ausgestattet mit einer Kompletteinhausung für den Lärmschutz und einer Video-Überwachung, die den gesamten Arbeitsbereich erfasst.
Ihre Vorteile auf einen Blick:
- Präzise 5-Achs-Bearbeitung für komplexe CFK-Bauteile
- Effiziente Prozessführung mit voller Sicht auf den Arbeitsbereich
- Sicherer und lärmarmer Betrieb dank geschlossenem Bearbeitungsbereich
Das sagt unser Kunde:
„FOOKE verfügt über hervorragend qualifizierte Fachleute, die sehr wirtschaftliche Lösungen entwickeln und sie pünktlich und genau umsetzen. So etwas erlebe ich selten.“
– Hans-Jochen Platte, Produktionsleiter, GKN
FOOKE liefert maßgeschneiderte Lösungen, die Präzision, Effizienz und Wirtschaftlichkeit in der Luftfahrt verbinden.
Do You Machine Horizontal Beams and Crossbeams?
Beams | Crossbeams
For the high-precision machining of large structural components such as beams and crossbeams, FOOKE relies on the ENDURA® 715LINEAR gantry milling machine aerospace solution. In a single setup, all machining operations, from roughing to underside machining—are completed efficiently and precisely.
Your Benefits at a Glance:
- Complete Machining in One Setup: No multiple changeovers, maximum precision
- Short Setup Times: Efficient clamping concept with the MakroGrip system
- Highest Dimensional Accuracy: Roughing, finishing, and underside machining in a single process
The Result: Significantly reduced machining times, stable processes, and reproducible quality for complex carbon fiber and aluminum structures.
FOOKE delivers manufacturing solutions that combine precision, efficiency, and process reliability, perfectly suited for the most advanced aerospace structures.
Guaranteed Accuracy with FOOKE Certified Precision
Wing Structure
Certified Precision for Wing Section Manufacturing.
For the certification of component machining on a wing section of the Dornier Eco 328, FOOKE developed a highly precise manufacturing solution to ensure maximum quality and process reliability. The component, representing one-third of the lower wing half, was produced from AL7475 according to Dornier standards and machined with the highest dimensional accuracy.
Your Benefits at a Glance:
- Certified Precision: Complies with all Dornier specifications and aerospace standards
- Significant Weight Reduction: From 220 kg raw part to 15 kg finished component
- Short Lead Times: Complete machining in just 2 hours and 17 minutes
- Process Reliability: CAM programming with Tebis and control via Heidenhain TNC 640
The Result: A fully validated manufacturing process that meets the highest quality requirements and lays the foundation for series production.
FOOKE delivers solutions that perfectly combine precision and productivity, providing sustainable and future-proof aerospace manufacturing.
Cut Machining Time by 50 Percent
Helicopter | Base Plate
Optimizing Helicopter Base Plate Manufacturing with FOOKE ENDURA® 715LINEAR
To optimize the production of aluminum helicopter base plates, our customer relied on the FOOKE ENDURA® 715LINEAR gantry milling machine aerospace solution.
Through close, collaborative partnership and innovative manufacturing strategies, we achieved a 50 percent reduction in machining time.
The combination of highest precision and efficient five-side machining ensures:
- Significant Process Optimization
- Future-Proof Manufacturing Solution
- Stable Processes and Reproducible Quality, even for safety-critical applications
FOOKE delivers technologies that merge maximum efficiency and precision for the aerospace and defense industries.
High Material Removal for Space Applications
Large-Format Aluminum Structural Components
Precision and High Material Removal for Large Aerospace Aluminum Structures
In the aerospace industry, precision can determine the success or failure of a mission. FOOKE provides solutions specifically tailored for machining large-format aluminum structural components with maximum efficiency, process reliability, and surface quality.
Our powerful gantry milling machines enable high-volume material removal, even for extremely large workpieces. Thanks to high removal rates and dynamically rigid machine structures, up to 90 percent of the raw material can be efficiently machined while maintaining maximum dimensional accuracy and minimal processing times.
Seamless finishing ensures smooth, high-quality surfaces without detectable transitions—a critical requirement for the demanding surface standards in aerospace applications.
Integrated metrology allows on-machine quality assurance, capturing and analyzing deviations in real time to guarantee process stability and precision at all times.
The Result:
An optimized, end-to-end manufacturing process that saves material, time, and costs while delivering the quality demanded by the aerospace industry.
Efficient Carbon Fiber Machining
Helicopter Cockpit Doors
FOOKE ENDURA® 907LINEAR | High-Precision CFK Machining for Aerospace
The FOOKE ENDURA® 907LINEAR gantry milling machine aerospace solution produces carbon fiber components with exceptional precision, including helicopter canopies and A350 XW cockpit doors.
Our aerospace solution offers:
- Versatile Machining: Milling, drilling, and threading of CFK, GFK, aluminum, and titanium
- Short Setup Times: Automatic lift door, custom clamping devices, and pallet change system
- Maximum Flexibility: Adjustable machine tables for different components
With the ENDURA® 907LINEAR, efficient CNC machining starts with the right machine, combining precision, flexibility, and speed in a single system.
Experience how FOOKE elevates your aerospace manufacturing to the next level.
Clamping, Aligning, and Drilling in a Single System
Fuselage Drilling | Vertical Stabilizer
Setting New Standards in Titanium Bushing Machining for Vertical Stabilizers
FOOKE sets new benchmarks in machining titanium bushings for vertical stabilizers. With our dedicated drilling stand and integrated clamping system, we perform fuselage drilling as well as drilling and spindling of the vertical stabilizer in a single system—efficiently, precisely, and reliably.
Your Benefits at a Glance:
- Efficient Process Integration: Clamping, aligning, and drilling in one machine
- Maximum Flexibility: Capable of vertical and horizontal machining
Highest Precision: Integrated quality control including measurement and QA checks
We deliver optimized manufacturing solutions that meet even the most demanding aerospace requirements.
Curious About Our Aerospace Milling Machine Solutions?
Get in Touch!
Our Sales Team – Aerospace Milling Machine Experts You Can Trust
Our sales team consists of experienced aerospace professionals with over 20 years of industry expertise. We provide competent, personalized, and practical advice, from selecting the right milling machine aerospace solution to complete turnkey systems.
Get in Touch:
Write to us or call directly. We will answer your questions as quickly as possible and look forward to speaking with you.
Phone: (248) 218 5880
E-Mail: info[at]fooke-usa.com
Our Aerospace Milling Machines – Preferred by Market Leaders Worldwide
AIRBUS │ AIRBUS HELICOPTERS │ ALBANY | BOEING | BEYOND GRAVITY | COMAC | GKN AEROSPACE | FOKKER │ HARBIN AIRCRAFT │ HIZE AERO │ LO-CAT SYSTEMS │ NORTHROP GRUMMAN | PILATUS AIRCRAFT │ PREMIUM AEROTEC │ SPACE X | VAST SPACE | …
All-in-One Precision Solutions for Aircraft and Space Components
FOOKE TURNKEY SOLUTION
FOOKE understands the complex demands of the aerospace industry—from efficient machining of high-strength materials to comprehensive quality assurance.
With the FOOKE turnkey solution, you get far more than just a machine: you receive a fully integrated, end-to-end manufacturing process, perfectly coordinated from the initial concept to a production-ready solution.
Process Consulting & Development
We analyze your specific manufacturing tasks and develop customized machining strategies, along with tailored machining and measurement programs, to ensure the highest precision and maximum efficiency.
Technology & Machine Concept
Whether milling, friction stir welding, or waterjet cutting, we configure every machine precisely to your requirements. Our FEM-optimized machine structures, tailored tooling, and integrated chip and dust extraction systems ensure stability, cleanliness, and process reliability at the highest level.
Component Handling
Streamlined Material Flow for Maximum Efficiency
From material storage and pallet systems to intelligent control, FOOKE automates your processes to ensure smooth material flow and reduced lead times.
Metrology
Integrated Measurement Systems for Maximum Accuracy
Integrated measurement systems capture component deviations and positions with high precision, providing valuable data for your quality assurance.
Clamping Technology
Our tailored clamping concepts and flexible systems—manual, semi-, or fully automated—ensure stable processes and maximum repeatability.
Demo and Application Center
In our technology center, we conduct preliminary trials, tests, and feasibility studies. This allows you to gain solid results and planning reliability even before implementation.
Process Integration & Monitoring
We support you during implementation, monitor ongoing processes, and document all data for your quality assurance, ensuring a transparent and reliable production.
Workshop Management
From foundation design to airflow and noise protection, we plan your production environment holistically, creating the optimal foundation for your manufacturing operations.
Your Advantage
With FOOKE as your partner, you benefit from a comprehensive solution that perfectly integrates technology, processes, and infrastructure.
Efficient. Precise. Future-Proof.
Precision Across Every Aerospace Material
Carbon Fiber Reinforced Plastics
Machining CFK (carbon fiber reinforced plastics) and GFK requires specialized expertise and equipment due to the unique properties of these composites. FOOKE gantry milling machines deliver outstanding precision for every task, whether trimming, drilling, or milling composite materials, or manufacturing complex structural components such as fuselage panels, wing sections, or cockpit elements.
Key considerations in aerospace composite machining include:
- Fiber Integrity: Maintaining the structural strength of carbon fibers while avoiding delamination or fraying.
- Dimensional Accuracy: Achieving tolerances often within micrometers, critical for assembly in aerospace applications.
- Surface Quality: Producing smooth, consistent surfaces to meet aerodynamic and structural standards.
- Tool Wear Management: CFK is highly abrasive, so optimized tooling and tool paths are essential to maintain precision and minimize costs.
- Dust and Safety Control: Carbon fiber dust is hazardous; FOOKE integrates intelligent extraction systems at the milling head and room-level extraction to ensure a clean, safe environment.
By addressing these challenges, FOOKE ensures a reliable, high-precision milling process that meets the rigorous standards of the aerospace industry, enabling manufacturers to produce lightweight, durable, and high-performance components with confidence.
Precision Across Every Aerospace Material
Aluminum Machining
Machining aluminum in aerospace applications requires both high dynamics and absolute precision. FOOKE 5-axis gantry milling machines handle large-format components as well as complex geometries with ease.
Key considerations for aluminum machining in aerospace include:
- High Material Removal Rates: Aluminum allows faster cutting speeds, but requires careful balance to avoid vibration or chatter on large or thin-walled components.
- Dimensional Accuracy: Tight tolerances are critical for assembly and aerodynamic performance of aircraft structures.
- Surface Quality: Smooth surfaces reduce post-processing and ensure proper aerodynamic behavior.
- Thermal Management: High cutting speeds can generate heat; optimized tool paths and cooling strategies prevent warping and maintain precision.
- Tool Optimization: Selecting the correct cutting tools and coatings ensures long tool life and consistent machining results.
- Efficient Chip Management: Aluminum chips are sharp and conductive; proper extraction and handling prevent machine damage and maintain a safe work environment.
FOOKE optimizes feed rates, spindle speeds, and tool selection while implementing efficient chip management systems, ensuring clean, precise, and cost-effective aluminum components.
Our solutions are ideal for producing aircraft structures and fuselage skin segments, combining speed, accuracy, and reliability for the aerospace industry.
Precision Across Every Aerospace Material
Titanium Machining
Titanium is exceptionally strong yet difficult to machine. FOOKE milling machines are specifically designed to meet these challenges: they provide the stability needed to handle high cutting forces while maintaining tight tolerances.
With thermally optimized, vibration-damped milling concepts, FOOKE minimizes tool wear and ensures reliable, repeatable machining, even for complex titanium components.
Key advantages for aerospace titanium machining include:
- High Structural Integrity: Maintains material strength during high-force cutting.
- Tight Dimensional Accuracy: Essential for assembly and performance of aerospace structures.
- Optimized Tool Life: Advanced spindle and feed control reduce wear and maintenance costs.
- Process Reliability: Consistent results even on large or geometrically complex components.
FOOKE solutions are ideal for high-performance aerospace components, delivering precision, efficiency, and reproducibility for even the most demanding titanium applications.
High-Precision Aerospace Milling Machine Solutions in Action
Discover FOOKE Machine Examples for Complex Aerospace Components
Aluminum Aerospace Profiles
Machining on the ENDURA® 1100LINEAR Gantry Milling Machine
The ENDURA® 1100LINEAR is designed for high-precision milling of aluminum profiles for the aerospace industry. Its lateral machine construction and linear direct-drive axes enable dynamic yet highly accurate machining, even for large or thin-walled extruded profiles.
Precision Clamping for Complex Profiles
Aluminum profiles are securely held and precisely aligned using a specially developed clamping device with a three-jaw chuck. This ensures repeatable, accurate machining of complex cross-sectional geometries, as required in aerospace applications.
Key Benefits:
- Exceptional precision for thin-walled and large-volume profiles
- Dynamic machining with linear direct-drive axes
- Secure clamping with three-jaw chuck for repeatable results
- Ideal for complex aluminum cross-sections in aerospace manufacturing
CFRP, GFRP, Aluminum, and Titanium Components
Machining on the ENDURA® 907LINEAR Gantry Milling Machine
The ENDURA® 907LINEAR is engineered for high-precision milling, drilling, and threading of components made from CFRP, GFRP, aluminum, and titanium. Thanks to its gantry-style construction and linear direct-drive axes, the machine delivers exceptional machining accuracy and repeatable positioning, even when handling complex geometries commonly found in aerospace parts.
Whether you are producing lightweight composite structures or high-strength metal components, the ENDURA® 907LINEAR ensures consistent quality, precise tolerances, and reliable performance for every part.
Sheet Thickness Measurement
Using Ultrasonic Probes
For high-precision milling of aircraft skin panels, an ultrasonic probe is used to measure the actual sheet thickness contact-free and in real time. This highly accurate measurement method allows the milling depth to be precisely adjusted according to local material tolerances, ensuring that the skin panels consistently meet required thickness specifications, weight limits, and structural quality standards demanded by the aerospace industry.
CFRP Components
Machining on the ENDURA® 907LINEAR Gantry Milling Machine
For components made from carbon fiber-reinforced plastics (CFRP), the ENDURA® 907LINEAR offers specialized machining capabilities, including milling, drilling, routing, cutting, and sawing. Its gantry-style construction, linear direct-drive axes, and automatic workpiece handling ensure high precision, repeatable accuracy, and maximum efficiency, even when processing sensitive composite materials.
3D Surface Milling
Thin-Walled Aluminum Aircraft Skin Panels
For high-precision machining of thin-walled aluminum aircraft skin panels, 3D surface milling is employed. This technique allows for the accurate replication of complex surface geometries while minimizing material usage.
By leveraging advanced milling technologies, highly precise machine controls, and customized clamping and measurement systems, the required tolerances, surface finishes, and structural strength demanded by the aerospace industry are consistently achieved.
Stringer Profile
for the Sukhoi Superjet 100
This component serves as a fuselage stringer in the primary structure of the Sukhoi Superjet 100. The stringer profiles are installed along the fuselage sections to provide longitudinal reinforcement of the fuselage skin. Due to their specific geometry and material design, the stringers contribute significantly to the structural strength, load distribution, and torsional rigidity of the aircraft fuselage.
The stringer profiles are machined with high precision on our ENDURA® 1000LINEAR long-bed milling machine, ensuring that the tolerances and surface quality requirements of the aerospace industry are consistently met.
Horizontal Tailplane Wings
and Other Components for Airbus Aircraft
The horizontal tailplane wings (HTP), along with various other components, are manufactured for all Airbus aircraft types. These parts are key structural elements of the aircraft, contributing significantly to flight stability, load distribution, and aerodynamics.
All components are machined on our high-precision FOOKE milling machines. By utilizing state-of-the-art milling technologies, fixtures, and clamping systems, we ensure repeatable, accurate production that meets the strict requirements of the aerospace industry.
Aluminum Profiles
Machining on the ENDURA® 1005LINEAR Gantry Milling Machine
The ENDURA® 1005LINEAR is designed for high-precision machining of aluminum profiles. It features a multi-flexible clamping system that can be adjusted in all axes, allowing for exact alignment of the profiles.
The combination of gantry-style construction, linear direct-drive axes, and flexible clamping technology ensures high machining accuracy, repeatable precision, and efficient production, even for complex profile geometries.
Composite Profiles
Machining on the ENDURA® 609LINEAR Gantry Milling Machine
The ENDURA® 609LINEAR is designed for high-precision machining of composite profiles. Its gantry-style construction and linear direct-drive axes ensure exceptional machining accuracy, repeatable precision, and safe handling of sensitive materials.
Highly Complex Spherically Shaped Components and Structural Parts
Machining on the ENDURA® 611LINEAR Gantry Milling Machine
The ENDURA® 611LINEAR is designed for high-precision machining of highly complex spherically shaped components and structural parts made from aluminum, carbon fiber (CFRP), and GLARE.
It enables the milling of large aluminum fuselage segments with dimensions of up to 551 x 46 x 31 in.. The combination of gantry-style construction, linear direct-drive axes, and precise clamping technology ensures exceptional machining accuracy, repeatable precision, and efficient production, even for highly complex geometries.