PRECISION UNDER PRESSURE, THE CRITICAL ROLE OF FINISHING IN AEROSPACE AND DEFENCE MANUFACTURING
Colin Spellacy, Head of Sales, Rösler UK
In aerospace and defence manufacturing, there is no margin for error. A single microscopic imperfection can compromise performance, shorten operational life, or, in the worst cases, lead to catastrophic failure. Yet, despite this reality, one vital aspect of production too often remains an afterthought, surface finishing.
At Rösler, we’ve spent 90 years refining the art and science of surface finishing. In that time, we’ve witnessed industries evolve, technologies disrupt, and materials advance. One thing hasn’t changed, however, and that is the fact that finishing is not simply cosmetic. Instead it’s functional, safety-critical, and central to the success of any high-performance component.
In aerospace and defence, sectors where lives depend on precision and reliability, this truth is amplified. Mass finishing and shot blasting are the silent forces enabling aircraft to fly safely, ships to withstand corrosive seas, and military hardware to endure the harshest environments. And yet, we still encounter manufacturers and suppliers who treat finishing as an operational necessity rather than a strategic priority.
It’s time to reframe the conversation.
WHY FINISHING IS MISSION-CRITICAL
In aerospace and defence, “good enough” isn’t a thing. A turbine blade’s surface texture affects airflow and efficiency. A fastener’s edge quality can determine whether it survives cyclic loading or develops fatigue cracks. Even a minor inconsistency in surface treatment can mean the difference between passing or failing rigorous quality audits.
Mass finishing and shot blasting are essential in meeting these demands. Mass finishing (through techniques like vibratory, centrifugal, and drag finishing) delivers controlled deburring, smoothing, and polishing of intricate geometries. Shot blasting, with its high-energy projection of abrasive media, not only cleans but also imparts beneficial compressive stresses, improving fatigue resistance and prolonging service life.
These technologies don’t just prepare components for coatings or assembly, they prepare them for survival in the harsh realities of aerospace and defence operations.
CHOOSING THE RIGHT PARTNER
Selecting a surface finishing partner isn’t about choosing a machine. It’s about selecting a collaborator that understands the stakes.
Here are the questions every aerospace and defence manufacturer should be asking:
- Does your short-listed supplier have a proven track record in safety-critical industries?
Aerospace and defence components are unlike any others. They require finishing processes validated to the highest standards, often with full traceability. Look for a supplier with decades of experience and established partnerships in these sectors, this is not an arena for newcomers learning on the job. - Is your short-listed supplier vertically integrated?
Finishing isn’t just about the machine; it’s about the interplay between machine design, process parameters, and media chemistry. A partner that designs and manufactures its own equipment and consumables can optimise the entire system, ensuring consistent, repeatable results. - Can your short-listed supplier offer bespoke solutions?
Standard, off-the-shelf systems often fail to meet aerospace and defence requirements. A credible partner should have the engineering capability to develop customised processes for complex geometries, exotic materials, and stringent tolerances. - Does your short-listed supplier understand the regulatory landscape?
From regulatory approvals to defence procurement standards, finishing suppliers must be fluent in the language of certification and compliance. - Is your short-listed supplier future-ready?
The aerospace and defence sectors are embracing lightweight materials, composite structures, and additive manufacturing (AM). A forward-looking partner invests in R&D to keep pace with these shifts, offering solutions for tomorrow’s challenges, not just today’s.
AM POST-PROCESSING FOR NEXT-GENERATION COMPONENTS
AM is transforming aerospace and defence by enabling designs previously thought impossible. But AM introduces new post-processing challenges such as powder residues, rough as-built surfaces, and delicate lattice structures.
At Rösler, we’ve approached AM not as an anomaly but as a natural evolution of manufacturing. Through our specialist sister company, AM Solutions, we’ve applied our deep surface finishing expertise to develop systems tailored to AM’s unique demands.
Take SLS and MJF plastic parts, for instance. These technologies produce complex geometries but leave parts encased in unsintered powder. Manual cleaning is inconsistent, labour-intensive, and unsuitable for production-scale throughput. AM Solutions’ 2-in-1 automatic depowdering and surface finishing solutions make post-processing repeatable, safe, and scalable, essential for aerospace and defence applications where part integrity is vital and safety critical.
The message is clear. AM parts are still parts. They require finishing just as much (if not more) than conventionally manufactured components.
A LEGACY OF INNOVATION AND PARTNERSHIP
Rösler’s 90-year history in industrial finishing has taught us one simple truth, surface perfection isn’t optional, it’s engineered.
In aerospace, shot peening strengthens landing gear and turbine discs to resist fatigue. Mass finishing polishes fuel system components to reduce friction and optimise flow. In defence, shot blasting prepares armoured vehicle components for protective coatings, while vibratory finishing ensures small, intricate parts like weapon system linkages meet exacting standards.
Our role is not just to supply machines but to partner with manufacturers, helping them navigate these complexities and achieve the highest levels of quality and performance.
RETHINKING FINISHING
Too often, finishing is viewed as the final hurdle between production and delivery. But what if we flipped the script? What if manufacturers treated finishing as a source of competitive advantage?
A proactive finishing strategy reduces rework, accelerates time to market, and improves product performance. It also opens doors to innovation. As aerospace and defence programmes push the boundaries of design, materials, and manufacturing methods, finishing partners must push boundaries too, investing in automation, sustainability, and digital integration to keep pace with Industry 4.0.
SUMMARY
In aerospace and defence, failure is not an option. Every part must perform flawlessly, under the most extreme conditions. Finishing isn’t peripheral to this mission, it’s at its heart.
As manufacturers seek to meet rising demands for quality, efficiency, and innovation, their choice of finishing partner will shape their success.
At Rösler, our legacy is built on more than machines. It’s built on trust, precision, and partnership, values that have guided us for nearly a century and will continue to guide us as we help our aerospace and defence customers meet the challenges of tomorrow.
Because in these industries, there are no second chances, and neither should there be in finishing.
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