Since 2005 when Exacta Machine, Inc. made the decision to change its name to Exacta Aerospace, Inc. to better reflect the core business, the company has launched a number of initiatives to help achieve the vision of becoming a leading supplier in the aerospace industry.  One of those initiatives was a partnership in 2007 with QMI SAI Global to attain AS9100 certification.  On June 20, 2007 Exacta was awarded the AS 9100 Rev. B: 2004 and ISO 9001:2000 Certificate of Registration.  (View our Certificate)  Although Exacta has a long history of embracing Continuous Improvement, the certification assures customers that Exacta's Quality Management System meets the highest standards recognized throughout the world.  After initial certification, Surveillance Audits are the heart of the process.  Exacta is pleased to announce that on January 16, 2009 the 24 month Surveillance Audit conducted by QMI SAI Global returned a score of 98.9.  The company was complimented on the efforts taken to flow down the quality policy and quality objectives to all employees.  Each year the quality objectives are refined and charted and each employee receives a card that contains the objectives along with the company's mission and vision statements.  The chart is also displayed throughout the facility.  According to Jarrod Young, Director of Quality Assurance at Exacta Aerospace, "the visual displays are a good reminder that quality is everyone's responsibility".

 One of the things HR Director Shawna Biggars tackled when she arrived at Exacta Aerospace in 2007 was to launch the company's first ever United Way Corporate Campaign.  Armed with previous campaign experience in the banking industry and great support from staff at Exacta and at The United Way of the Plains, Shawna had some good ideas for fund raising and promoting individual giving.  The efforts paid off with a fantastic inaugural campaign and set the bar high for 2008.  After months of hard work, planning and preparation, Shawna and co-chairs HR Assistants Vicki Keimig and Michelle Voegeli got busy tallying the results.  Thanks to the generous nature of Exacta's employees, the campaign for 2008 was an even bigger success.

The preparation for the campaign started in the summer and culminated the second week of October with special events being held to raise money.  Employees participated in a free-throw shooting competition, bake sale and mystery photo contest.  On the final day, every Exacta employee who signed up for payroll deducted contributions received chances to win one of many raffle prizes donted by the company, employees, customers, suppliers and local businesses.  The list of prizes is too long to list, but special thanks goes to Makino for their donation of a Richard Petty Driving Experience package.

As the fun-filled week drew to a close, it was clear that Exacta employees stepped up their efforts in spite of recent economic difficulties in the aerospace industry.  At a time when there is much uncertainty and many in our community are finding themselves in need, the Exacta team really came through.  When the final count was taken the numbers surprised us all.  Employee participation was up 22% and employee giving increased by an amazing 225%!  Shawna summed up the company's thoughts on the results "We are so proud of our employees' generosity and commitment to supporting our community through United Way and are already looking forward to next year's campaign!

In 2005 Exacta Aerospace moved to its current facility, expanding to over 175,000 sq. ft.  In 2008, as the company celebrates 30 years in business, we are proud to announce the largest capital investment in machinery and equipment in the company's history.  The following investments represent the latest in high-speed machine tool technologies and will greatly increase Exacta's ability to provide bigger, more complex monolithic parts.

Makino D500 - The newest 5-axis vertical machining center from Makino is ideally suited for manufacturing complex parts commonly asssociated with aerospace where part quality is paramount.

• Maximum workpiece is 25.6" x 16.5".  The X-, Y-, and Z axes provide strokes up to 21.6", 39.4" and 19.7"
• Rotary table axis A and C provide rotational motion of +30 to -120 degrees on the A-axis and 360 on the C-axis
• Capable of feedrates up to 1,968"/minute, with a 14,000 rpm high power spindle
• Utilizes 3 direct drive motors for C-axis rotary able and A-axis trunnion.  One controls C-axis motion. Two control motion in the A-axis, one at each end of the trunnion.  This design provides greater torque and rigidity.  Twist and torsion in the trunnion is eliminated to achieve superior dynamic accuracy.  Ulta-high torque DD motors provide superior acceleration that can slash cycle time of complex five-axis simultaneous machining applications by up to 60%  

Exacta will utilize full-scale automation by incorporating the new machine into the existing MMC2 pallet changer alongside the 3 existing Makino A51 horizontal machining centers.

Makino MAG3 EX - The MAG series of 5-axis machining centers are the ideal product for machining medium to large aluminum airframe components.  Unparalleled metal removal rates, elimination of setup time and superior chip management have set a new standard for manufacturing efficiency.

• Travels: X-157", Y-60", Z-40"  A Axis +/-110 degrees, C Axis infinite
• 33,000 rpm, 80 hp high speed articulating spindle
• Programmable feed rates up to 1,000" /minute
• Tool storage capacity 120 with tool changing time of 10 seconds
• 140" x 60" pallet size

The MAG3 EX will be integrated into a Makino Machining Complex (MMC) Automated Pallet Handling System to provide maximum spindle utilization and permitting unattended parts production.

Mazak Quick Turning Nexus 250MY - The Mazak QTN series delivers multi-tasking capability with milling and turning in a single set up.  Quick Turn Centers have achieved productivity improvements from 40% (in steel) to 80% (in aluminum).

• Chuck Size 10", Bar Capacity 3", Maximum Swing 26.5"
• Main Spindle 4,000 rpm - 35 hp, Rotary Tool Spindle 4,500 rpm
• Tailstock

Mazak Nexus 510C/50II - The Nexus II Series combines advanced technology, productivity and value to provide top performance.  The latest generation Mazatrol Maxtrix control has been designed to be the optimum system for machining centers making this the new generation world class vertical machining center.

• Travels X-41", Y-20", Z-23"
• Horsepower - 30 hp, Maximum speed: 6,000 rpm
• Tool Storage Capacity: 24, Tool Change Time: 2.0 seconds
• Spindle Taper: #50
• Full 4th axis rotary table

Mazak Integrex 200-IV ST - Integrex is the marriage of a high-powered turning center and a full-function machining center to produce parts in a single setup.  Done-In-One machining works to eliminate multiple setups, fixtures, tools, handling and waiting time.

• Chuck Size 8", Maximum Swing 12.99"
• Maximum Length 60"
• Main Spindle 5,000 rpm - 30 hp, Rotary Tool Spindle 12,000 rpm - 25 hp
• Lower turret for simultaneous cutting

The new machinery will enhance Exacta's existing capabilities, which include:

• Complex multi-axis milling and multi-axis mill/turn
• Kitting and Assemblies
• Broaching
• Gear Shaping
• Honing
• Grinding
• CNC Waterjet
• Sheet Metal Forming
• CMM Certified Measuring
• CAD/CAM, CATIA V5
• ERP System including full MRP

Exacta Aerospace, Inc. is a leading supplier to the aerospace industry.  Founded in 1978 in Wichita, Kansas our customers include The Boeing Company, Cessna Aircraft Company, Spirit Aerosystems, Bombardier/Learjet, Hawker Beechcraft, Gulfstream and Bell Helicopter.  Exacta is AS9100 REV. B: 2004 and ISO 9001:2000 certified.

When the leadership at Exacta Aerospace, Inc. decided to take a group of production managers to the International Manufacturing Technology Show (IMTS) last week in Chicago they had a higher purpose in mind than just a road-trip. For most of them this was their first time attending the premier manufacturing technology show in North America.  They had a chance to see more than 15,000 new machine tools, controls, computers, software and processes on display including the latest innovations from well-known manufacturers such as Makino, Mazak, Mori Seiki and traditional names like Hass Automation and Bridgeport.
While the group picked up a lot of good information, clearly the highlight of the show was getting their first glimpse of the newest member of the Exacta family, the Makino D500. The newest 5-axis vertical machining center from Makino, the D500 is ideally suited for manufacturing complex parts commonly associated with aerospace. According to Makino, it provides exceptional sustained dynamic accuracy setting a new standard for 5-axis machining accuracy. The work zone for the D500 is 500 x 450 mm. The X-, Y-, and Z-axes provide strokes up to 550 mm, 1000mm and 500 mm respectively. Rotary table axis A and C provide rotational motion of +30 to -120 degrees on the A-axis and a full 360 degrees on the C-axis. The D500 is capable of rapid rates up to 50m per minute and is equipped with a 14,000 rpm high power spindle. Makino utilizes three direct drive motors for the D500’s C-axis rotary table and the A-axis trunnion. One direct drive motor controls and C-axis motion. Two direct drive motors control motion in the A-axis, one at each end of the trunnion. The dual motor design provides greater torque and rigidity. Most importantly, twist and torsion in the trunnion is eliminated to achieve superior dynamic accuracy. The ultra-high torque DD motors also provide superior acceleration characteristics that can slash cycle time of complex five-axis simultaneous machining applications by up to 60%. To gain even more efficiency from the new machine, Exacta will utilize full-scale automation by incorporating the D-500 into the existing MMC2 pallet changer alongside the 3 Makino A51 horizontal machining centers.
Exacta’s General Manager, Ben Voegeli, felt the trip was a success. “We had a great visit to the show and I think it was a positive learning experience for everyone. I will never forget the first time we attended in 2002 and the show has only gotten better. This year I came back excited that Exacta is really staying on the cutting edge of technology. The new Makino D500 we have coming our way is the first one in North America and is absolutely awesome. At times during the show the crowd around the machine was so large you could hardly get close enough to see it.”

The D500 with MMC2 pallet changer drawing courtesy of Makino