Project Overview

The Challenge

A prime defense contractor required precision sheet metal structural assemblies and electronic enclosures for an airborne defense system program. The program was ITAR controlled, requiring a fabrication partner with documented ITAR registration, full material traceability, and compliance with AS9100 quality management standards.

Parts required certified material test reports (MTRs), in-process inspection documentation, and first article inspection (FAI) reports before production release. Tolerances of ±0.003″ on critical mating surfaces required consistent, repeatable precision across every production run. Delivery schedules were tied to program milestones with zero schedule flexibility.

The MJM Solution

MJM Manufacturing’s ITAR registered facility and AS9100 certified quality system made us a qualified source for this program from day one. We worked with the contractor’s engineering team through the first article inspection process, providing full dimensional inspection reports and material certifications before any production units were released.

Using our CNC fiber laser cutter for blank development and our press brake forming equipment for the structural bends, MJM maintained the ±0.003″ critical tolerances across the entire production run. TIG welding was performed by our certified welders on all structural joints, with each weld documented per the program’s quality requirements.

Anodizing and chemical film finish were coordinated through our trusted finishing partners, with MJM managing the full chain of custody and quality documentation. All 250+ assemblies were delivered on schedule across six production releases with no nonconformances reported.