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Callender Aerospace is a UK-based engineering company that focuses on manufacturing and delivering high-quality components, assembly solutions, and supply chain services for the aerospace, power generation, and other key industries. Established in 1974 by a small team of four, the company has grown to over 230 employees today. Over the years, Callender has evolved from machining early turbo-fan blades in 1988 to producing the first single-piece titanium forgings for the JSF Joint Strike Fighter in 1998. Today, it stands as a leading supplier in the blade market, offering comprehensive supply chain solutions to its customers.
The company’s expertise in blade manufacturing includes advanced techniques such as long strip friction welding. The production of blades from a single blank involves complex processes, with fast and accurate roughing methods playing a crucial role in efficiency.
In collaboration with Seco Tools, Callender has developed plug milling technology, which has significantly improved their roughing speeds—increasing them by three to four times, according to Steven Waddington, Senior Engineer at Callender Blade Processing. This partnership has not only enhanced productivity but also helped reduce costs while maintaining high-quality standards.
Recently, Seco Tools and Callender worked together on a challenging project involving parts with a diameter of 1.3 meters and a blade length of 430 mm. They used high-diameter cutters ranging from 32 to 100 mm, specifically the 217 and 220.79 models for plug milling. Additionally, Jabro Tool, a subsidiary of Sankai acquired last year, provided solid carbide tools for the same project.
Garry Dugdale, Callender’s chief blade programmer, highlighted the precision achieved using the ZT800 machining center: “We now machine the wings so finely that manual polishing is no longer necessary.†This level of accuracy is made possible through close collaboration between machine builders, tool suppliers, and operators, enabling efficient and high-quality titanium processing.