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Ti Gr5 / Al 7075 · ±0.01 Interface · −50% Weight · Mill Cert
ALB / 001 — 010

Pocket-Milled Topology
Aerospace Lightweight Brackets

Precision 5-axis machined aerospace lightweight brackets — Ti Grade 5 (Ti-6Al-4V) or Al 7075-T6, topology-informed pocket milling for up to 50% weight reduction vs solid billet. Interface accuracy ±0.01 mm, Ra 0.8 µm at fatigue-critical zones. Material mill certificates and FAI reports with every order. For flight structures, avionics mounting, UAV airframes, and satellite brackets.

Ti Gr5 / 7075
Material
±0.01mm
Interface
−50%
Weight
Get Instant Quote → View Our Work
PART DWG · ALB-000 FLIGHT BRACKET · Ti-6Al-4V · POCKETED · MILL CERT ISO 9001 · FAI · CMM
Topology Pocket Mill
R≥3 · Fatigue Zone
TOPOLOGY POCKET-MILLED BRACKET · TOP VIEW Ti-6Al-4V · 110×70×18 · 4 BOLT M6 · 50% MASS REDUCTION ⌀0.01 bolt pattern phantom billet POCKETS · TOPOLOGY-INFORMED R ≥ 3 fatigue zone SOLID 218 g → POCKETED 109 g · −50% SIDE PROFILE RIB + WEB · 50% LESS MASS MATERIAL · DENSITY Ti Gr5 (Ti-6Al-4V)4.43 g/cc Al 7075-T6 ◀2.81 g/cc Al 6061-T62.70 g/cc Invar 368.05 g/cc Invar: thermal-stable FATIGUE · FILLET Cyclic load ◀R ≥ 3 mm Static structuralR ≥ 1.5 Internal cornerno sharp Ra ≤ 0.8 fatigue zone BRACKET · TYPE CANTI ◀ STRUT BOX CLEVIS DFM REVIEW INCL. LOAD-PATH OPTIMISATION CERT · DOC Mill Certificate ◀heat lot · composition Cert of Conformancespec compliance FAI reportAS9102 fmt avail Ra profilometerfatigue zone ISO 9001:2015HXC certified SCALE 1:1 · MM
Aviation · Defence · UAV · Satellite · Rocketry
Applications
Ti Gr5 · Al 7075 · Al 6061 · Invar 36
Materials
48hr Quote · 5-Day Al · 8-Day Ti
Service
Ti Gr5 / 7075
Material Standard
aerospace alloys
±0.01mm
Interface Accuracy
all mounting faces
−50%
Weight Reduction
vs solid billet
5–8 Days
Fastest Delivery
Al 7075 prototype
Why It's Difficult

Aerospace Bracket Challenges

Aerospace brackets must meet strict weight, strength, and accuracy requirements — with process traceability and material certification at every step.

⚖️
Weight with Certification
Aerospace brackets must be as light as possible with full material certification traceability. HXC provides material mill certificates and certificate of conformance with every aerospace order.
⚡
High-Cycle Fatigue
Aerospace structures experience millions of load cycles. HXC specifies minimum fillet radii (R ≥ 3 for cyclic), eliminates sharp stress concentrations, and verifies surface finish (Ra ≤ 0.8 µm) at fatigue-critical zones.
📐
Interface Accuracy
Avionics and flight control brackets have strict interface tolerances — ±0.01 mm for bolt-pattern positions, ≤ 0.005 mm for datum face flatness. All verified by CMM and reported.
Our Work

Aerospace Lightweight Brackets We've Made

Real CNC machined aerospace lightweight brackets — CMM verified, fully certified.

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How It Works

From Drawing to Finished Part

Upload your 2D/3D file — DFM feedback, quote, and confirmed lead time within 48 hours.

01
Upload Drawing
STEP, DXF, PDF. Include material spec + documentation requirements.
02
DFM & Quote
Free DFM — load-path review, fillet radii, fatigue zones. Quote in 48 h.
03
5-Axis CNC & FAI
5-axis CNC, CMM inspection, first-article inspection report.
04
Ship Worldwide
Mill cert + CoC + FAI enclosed. DHL / FedEx / sea freight.
Reviews

Trusted Aerospace Bracket Manufacturer

★★★★★
"Mill certificate, FAI report, and dimensional inspection all included as standard — documentation package was complete on first delivery. Lead time exactly as quoted."
AK
Alex K.
Stress Engineer · Germany
★★★★★
"HXC's DFM review identified two fatigue-critical fillets that should be increased — saved us a development iteration. Quality is consistent across batches."
SL
Sophie L.
Design Engineer · France
★★★★★
"Three years sourcing flight-qualified brackets from HXC. Material traceability is impeccable, the engineering team understands aerospace requirements thoroughly."
JT
James T.
Senior Buyer · UK
FAQ

Aerospace Lightweight Brackets — FAQ

Common questions answered by our manufacturing team.

Ti Grade 5 (Ti-6Al-4V): highest specific strength (880 MPa / 4.43 g/cm³), excellent fatigue resistance, widely qualified in aerospace. Al 7075-T6: most common for non-structural brackets — 503 MPa / 2.81 g/cm³, 65% lighter than titanium. Invar 36: for temperature-sensitive instrument mounts. Material mill certificates with every order.
HXC provides: Material mill certificate (alloy composition, heat number); Certificate of Conformance (CoC); First Article Inspection (FAI) report (full CMM dimensional); Surface finish measurement report. HXC is ISO 9001:2015 certified.
Topology-informed pocket milling removes material from non-load-bearing zones identified by FEA or load-path analysis — creating an organic pocket network that achieves near-optimal stiffness-to-weight. HXC implements topology results from customer FEA, or performs structural review as part of DFM.
Fatigue crack initiation is surface-finish sensitive. At fatigue-critical zones (tight fillets, loaded holes), HXC machines to Ra ≤ 0.8 µm and verifies with a contact profilometer. Shot peening is available as an optional surface treatment to introduce compressive residual stress.
HXC is ISO 9001:2015 certified (not AS9100). For customers requiring AS9100 Rev D documentation standards, HXC can provide equivalent documentation in AS9102 format: material certs, FAI dimensional reports, process records, and CoC. Please specify your documentation requirements at enquiry.
MOQ is 1 piece for prototypes and development builds. Production orders: no minimum. HXC regularly produces single prototype aerospace brackets for development testing, scaling to 500+ production pieces when the design is qualified.
Yes — HXC accepts customer-furnished material (CFM) in bar, plate, or billet form. We inspect CFM on receipt (dimensional verification and material spectral check) and return any remainder with the finished parts. Traceability is maintained throughout.
Ti Grade 5 prototype (including FAI): 8–12 days. Al 7075 prototype: 5–8 days. Production batch: 14–22 days. Rush orders available for development programmes — contact us.
Get a Quote

Send Your Drawing.
Get a Quote.

Every enquiry includes a DFM review — tolerance feasibility, material confirmation, and process approach confirmed before production starts. MOQ 1 piece.

24hr
Quote Response
MOQ 1
Prototypes OK
ISO
9001:2015
📐
DFM Review on Every Enquiry
Tolerance feasibility, fixturing strategy, and material confirmation. Specific, actionable feedback — not generic pushback.
🎯
First Article Inspection — Standard
FAI report on every new run. Material certs and surface treatment certs included with every shipment.
🔄
Same Process: Prototype to Production
Process plan from your prototype applies to production batches. No re-qualification when you scale.
⚙
3 / 4 / 5-Axis CNC + Turning
Complex structural parts, shafts, housings, and transmission components. Metals and engineering plastics.
ISO 9001:2015 3/4/5-Axis Milling CNC Turning CMM Inspection Global Delivery