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Aerospace CNC Machining: All You Need To Know

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The high level of precision required within the aerospace industry makes CNC machining an indispensable tool for prototyping aerospace components to meet the highest industry standards. CNC machining is essential in the aerospace industry as it enables the production of high-precision, reliable, and innovative components for prototyping applications where aerospace CNC machining allows engineers and manufacturers to achieve precise and accurate outcomes. In this guide, discover the benefits of CNC machining for aerospace prototyping and how this manufacturing process offers robust and reliable solutions in the aerospace industry.

Aerospace CNC Machining For Prototyping Applications

CNC machining processes are essential in the aerospace industry as they enable the production of high-precision, reliable, and innovative components for prototyping applications. These manufacturing processes allow engineers and manufacturers to achieve precise and accurate outcomes regardless of the quantity of parts produced, be it a single piece or thousands of parts. The following are some advantages associated with CNC machining in aerospace prototyping:

High precision: CNC machining offers the high level of precision necessary to produce aerospace prototyping components which ensures that prototypes match final designs closely.

Rapid iteration: CNC machining facilitates quick production and modification of prototypes which speeds up the development process.

Complex geometries: It is possible to produce complex shapes and intricate details with CNC machining that are crucial for many aerospace components.

Consistency in results: CNC machining ensures that results are consistent and repeatable which is essential for testing and validation.

Utilizing Foam For Aerospace CNC Machining And Prototyping

Foam is typically used in aerospace CNC machining for numerous purposes, including prototyping and rapid iteration. Foam is utilized to produce prototypes of aerospace parts before machining them from more expensive materials such as metals or composites. CNC machining enables precise shaping and detailing of foam prototypes based on CAD models, which allows engineers to identify potential problems early in the development phase and complete the necessary adjustments to enhance performance and manufacturability. In addition, foam can be used to create molds, patterns, and templates for the production of aerospace prototype components. The foam molds can be CNC machined to fit exact specifications and facilitate the production of consistent and precise parts for the prototyping process.

Optimize Aerospace Prototyping With Streamline Automation’s FROG3D® Line Of Products

Integrating FROG3D® CNC machining into automated production lines significantly facilitates prototyping efficiency in the aerospace CNC machining sector. CNC machining reduces human errors and delivers consistent quality across all machined components which proves essential in the aerospace prototyping landscape. Our CNC machining technology accelerates the prototyping process which allows for swift iterations and thorough testing of aerospace components. This agility ensures optimal design, functionality, and adherence to demanding industry standards, and significantly reduces development timelines. With Streamline Automation’s FROG3D® System, manufacturers have the capabilities to facilitate aerospace prototyping applications such as fuselages, wings, seats, and model aircraft in addition to UAVs and drones. To create products for these applications, foam is an excellent material as it is lightweight, easy to machine, has good strength-to-weight ratios, and provides essential structural flexibility which makes it ideal for prototyping and small-scale production.

Every successful product begins with a good design. When designing the fuselage, wings, and seats for prototypes in the aerospace industry, the process begins with a CAD (Computer-Aided Design) program which ensures that the product model includes necessary details such as mounting points, internal compartments, and aerodynamic features. This is followed by importing the CAD model into CAM (Computer-Aided Manufacturing) software that generates the toolpaths, and the CAM software converts the 3D model into instructions that the CNC machine can follow. The next step involves selecting the appropriate foam to fulfill the needs of the project at hand, and commonly utilized foams in CNC machining include EPS (Expanded Polystyrene), XPS (Extruded Polystyrene) and polyurethane foam. Each foam type has its own features and characteristics in terms of density, strength, and machinability. 


The FROGMill™ is an indispensable tool in aerospace prototyping as it can create complex geometries and features by removing material from a workpiece using rotary cutters. CNC machining aerospace parts are complex and often come in variations, so we advise to configure many of these parts with 4-axis milling machines. 4-axis CNC machining requires the operation of a machine using precise CNC where the process moves cutting tools and parts across up to 4 axes at the same time. The aerospace prototyping industry is ever-evolving, so continuous reconfiguration and adaptation of components is possible with 4-axis CNC machining and this is where our FROGMill™ machine proves its value. When producing components for aerospace prototyping applications, the FROGMill™ can prepare the foam block to the approximate dimensions required before it is sent to the FROGWire™ for milling.


Complex aerospace parts typically have curved surfaces, intricate shapes, and tight tolerances. Curved surfaces can be challenging to create without the capabilities offered by multi-axis CNC machining. The FROGWire™ is our advanced hot wire foam cutting machine which helps in creating complex tapered parts using advanced tapered cutting capabilities. It is possible to create multi-sided cuts using multiple profile shapes created from a 3D model with the ease of 2, 3, and 4-axis hot wire cuts, with fast cutting speeds featuring a maximum cutting speed of 50” per minute based on Type 1 EPS foam.   With Streamline Automation’s FROG3D® 4-axis CNC hot wire machine, aerospace prototype applications can be created with enhanced precision and consistency.


Producing prototype applications for the aerospace industry requires extremely tight tolerances and intricate geometries. Consequently, using the correct router bits ensures that the desired shapes and dimensions are achieved accurately, which minimizes errors and costly rework. In addition, the quality of the surface finish of parts is essential in aerospace prototype applications because it can affect the aerodynamics, fuel efficiency, and structural integrity of the end-user product. Selecting the correct router bits helps to achieve the desired surface finish, regardless of whether it is a smooth and polished finish or a textured finish for bonding purposes. 

The appropriate CNC machining tools are essential to enhance manufacturing productivity, all extreme precision and accuracy, ensure flexible production, and guarantee that products are consistent each time. Our FROGTools™ are durable and engineered specifically for milling EPS and polyurethane foam, including regular and tapered cutters in ball end and end mill styles. When used with the FROGMill™, FROGTools™ ensures that your aerospace CNC machined components are milled with extreme accuracy and attention to detail.


At Streamline Automation, our CNC machining solutions provide the exceptional precision required to produce aerospace prototype components and facilitate the adherence to strict performance and safety standards. Our line of FROG3D® equipment enables the production of aerospace prototype applications with intricate geometries that traditional methods cannot achieve which offers our customers a competitive edge in the aerospace manufacturing industry. Our CNC machining aerospace technology streamlines the prototyping process, thus allowing swift iterations and thorough testing of aerospace components. This capability ensures optimal design, functionality, and adherence to demanding standards in the aerospace industry which helps to significantly minimize development timelines. Integrating FROG3D® CNC machining into automated production lines will significantly uphold your business’s prototyping efficiency in the CNC machining aerospace sector. 

When you select the FROG3D® System for your aerospace CNC machining requirements, your prototyping processes will have a high degree of repeatability, capability to produce accurate parts, and meet tight tolerances while completing high-volume production with the highest quality standards. To get started with our cutting-edge CNC machining solutions that include machine tools, expert training, software, and ongoing support, contact us today at 403-250-1073 or drop us an email at [email protected] to ensure that FROG3D® equipment remains an essential resource for your manufacturing needs.

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