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expertise in production processes that enable collaboration with the customer, tighter quality control, and speed in manufacturing. When you’ re working with obsolescence issues and recreating old manufacturing processes, control is critical.”
This becomes increasingly valuable as defense operators seek to sustain platforms that remain in service long after original production lines have closed. In many cases, making a replacement component takes more than just having a drawing. You must rebuild the production know-how, too.
One recent example is the E-3 Bogie Beam program with Boeing. Delivering the first fully assembled version of the component required D-J Engineering to qualify new processes, reverse engineer legacy methods, and work closely with stakeholders, effectively rebuilding manufacturing knowledge alongside production capability.“ The E-3 Bogie Beam was challenging for several reasons, including outdated axle and truck assembly processes, complex plating, and a limited number of qualified outside processors on Boeing’ s approved vendor list,” Chris explains.
He adds,“ We worked directly with Boeing, got D-J Engineering qualified for new processes, reverse engineered what was necessary, and developed assembly techniques for a part that hasn’ t been built in decades.” This project ultimately repositioned the company within the program.“ Now, we’ re the industry experts in E-3 Bogie Beam production.”
Space launch represents another area of growth for D-J Engineering. The company has supplied components to space programs for more than a decade and currently manufactures over 100 parts for the Artemis program. That work draws on expertise in large-format structures and advanced materials, including Airware 2050, an aluminum-lithium alloy increasingly used in aerospace applications where performance and weight considerations play a significant role.
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