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Upon completion of the first construction drawings, work
in the shop began.
Every part was cut from sheet aluminum with the help of computer-controlled
laser and water jet cutting machines. Working with the laser allows us to
cut sheets of all sizes and shapes; the laser beam melts the aluminum and
creates a cut that is a mere 0.5 mm wide. In the case of the water jet
cutter, the actual cutting is done with very fine-grained sand, which is
transported by a thin, high-pressure water jet. The advantage of the water
jet cutter is obvious: the temperatures generated on the cutting surface
are
very low, which allows us to cut pretty much any part from any material we
otherwise wouldn’t be able to handle.
After we’ve cut all the parts (including all the necessary rivet
holes) we
start the process of bending and folding the aluminum sheets. Just like
the
cutting, this work couldn’t be done without the help of computerized
bending
machines. Spherical parts like wings tips, oil coolers, air vents or the
huge engine cowl are first hammered into shape over wooden plugs and then
welded together.
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