CAMM Metals Leveraged Laser Tube Cutting to Solve a Complex Aerospace Assembly Challenge
When aerospace projects demand tight tolerances, complex geometries, reliable repeatability, and efficient processing, choosing the right manufacturing partner matters. This case study highlights how laser tube cutting helped CAMM Metals develop a successful, repeatable solution for a challenging aerospace ground support component through engineering collaboration and our deep understanding of precision fabrication services.
The Project: An Aerospace Ground Support Component
This project centered around an aerospace ground support assembly made up of multiple round tube components. The design itself dated back to 1977 and required a series of compound cuts that needed to fit together accurately for welding and final assembly.
Initially, the customer approached us with a relatively straightforward concept involving laser cutting and bending of flat sheet metal parts. After reviewing the drawings, our team recognized an opportunity to add value. We had recently invested in advanced laser tube cutting equipment, and we reached out to the customer’s engineer to suggest moving the round tube components to the tube laser instead of leveraging our CNC machining services as they originally thought would be necessary.
That conversation changed the scope of the project and dramatically improved its outcome.
The Challenge: Proper Fit and Engineering Alignment
Our undertaking: Cutting round tubes that fit together perfectly
The biggest challenge was achieving a proper fit between multiple round tube parts. Cutting round tubes so they mate cleanly is far more complex than flat sheet work, especially when compound angles and tight tolerances are involved.
The real hurdle wasn’t just the machine; it was engineering. Designs that work perfectly in CAD don’t always translate seamlessly to real-world manufacturing. Our engineers had to redesign certain features so that once the parts came off the tube laser, they would assemble and weld together correctly.
This is where in-depth experience in precision sheet metal fabrication makes all the difference.
Marrying design intent with machine capabilities
There was also a learning curve for both sides in understanding the limitations and strengths of laser tube cutting. We ran a full kit of prototype parts and provided them to the customer with a simple request: tell us what works and what doesn’t.
Their engineer visited our fabrication shop, saw the tube laser in action, and worked directly with our engineering team. Together, we modified cutting programs, tested revised geometries, and refined the process until the results met expectations.
The Solution: Prototyping, Testing, and Collaboration
Prototyping as a problem-solving tool
The project consisted of five total assemblies, each made up of roughly 12 tube components. We began by cutting one complete prototype kit using our tube laser, allowing the customer to validate fit and function before full production.
This collaborative approach eliminated downstream surprises and ensured the final design was optimized for manufacturability.
Why laser tube cutting made the difference
By shifting these parts from CNC machining to laser tube cutting, we eliminated several headaches for the customer:
No complex fixturing for round tubes
Faster processing compared to CNC machining
Cleaner, more consistent cuts for welding
Improved repeatability for future production runs
Instead of outsourcing multiple operations, the customer could rely on one partner for laser cutting services and welding processes.
Results: A repeatable, scalable aerospace solution
The final outcome was a successful prototype, followed by production-ready parts that assembled and welded exactly as intended. Additionally, this project is expected to repeat, turning what started as a one-off request into an ongoing partnership.
Why Choose CAMM Metals for Your Complex Projects?
This case study shows what happens when laser tube cutting, engineering expertise, open communication, and a collaborative partnership come together. From redesigning legacy components to supporting unconventional geometries, our team thrives on solving complex manufacturing challenges.
We enjoy working side-by-side with customers at every level, from engineers to estimators to shop leadership. Whether the design is brand new or decades old, our team brings flexibility and a problem-solving mindset to every project.
If you’re looking for a partner who understands how to turn complex tube designs into reliable, high-quality parts, laser tube cutting at CAMM Metals may be the solution you didn’t know you had.
Request a quote to get started on your next project.