At CAB, the manufacturing of complex metal components can be managed through an integrated process that combines engineering, tooling design, sheet metal processing and forming, CNC machining, welding, heat and surface treatments, priming, painting and assembly.
This approach addresses a practical need: avoiding the treatment of each stage as an independent operation when, in actual production, decisions made during one process can directly affect those that follow.
A geometry defined during the engineering phase can influence forming; welding may introduce distortions that must be considered during subsequent CNC machining; heat treatment can alter the metallurgical condition and dimensional stability of the component; and a surface treatment must remain compatible with tolerances, fits and subsequent finishing operations. Finally, during assembly, the effects of the different manufacturing stages must converge while maintaining the geometry and functionality required by the design.
For this reason, in more complex projects, the value does not simply lie in assigning multiple processes to the same supplier. It lies in coordinating the manufacturing cycle as a whole, maintaining continuity between design, production, special processes, inspection and assembly.
This is the industrial model we have developed through our experience in the aeronautical and aerospace industries: we can support customers with an individual manufacturing process or follow the component through multiple stages, up to the production of finished parts, structures and subassemblies ready for subsequent integration.
Why Should a Complex Metal Component Be Considered as a Single Manufacturing Cycle?
Because the final result depends not only on the quality of the individual operations, but also on how those operations interact with one another.
A component may undergo numerous transformations before it is completed. The material may be cut and formed, certain surfaces may be machined, different parts may be welded together, and the component may then require heat treatment, surface protection and finally assembly.
Each of these activities can modify the conditions created by the previous stage or required by the next one.
For example, forming can generate springback and dimensional variations that must be considered before subsequent CNC machining. Welding can introduce distortions that need to be anticipated during fixture design. Heat treatment can affect the dimensional stability of the part. Similarly, the thickness and characteristics of surface treatments must remain compatible with subsequent assembly operations.
The issue is therefore not simply determining which processes are required, but correctly defining the sequence in which they should be performed and the conditions that must be maintained between one stage and the next.
This principle forms the basis of our approach to manufacturing complex components.
Which Manufacturing Stages Can CAB Integrate in the Production of a Metal Component?
At CAB, we can support the component throughout different stages of the manufacturing process, starting from engineering and extending, when required, through to final assembly.
The process may include:
- engineering, 3D modelling and manufacturability assessment;
- design and production of dies, fixtures and tooling;
- sheet metal cutting, processing and forming;
- CNC machining;
- welding;
- heat treatments;
- chemical, galvanic and surface treatments;
- application of primers and technical coatings;
- structural assembly and subassemblies;
- inspection and management of documentation associated with the manufacturing cycle.
This does not mean that every project must necessarily go through all of these stages.
We can be involved in a single manufacturing operation or take on a broader role within the production process, depending on the drawing, customer specifications and required scope of supply.
The key difference lies in our ability to connect these capabilities whenever the project requires it. Engineering, manufacturing, special processes and assembly are therefore not simply adjacent departments, but can become coordinated parts of the same production cycle.
What Role Does Engineering Play Before Production Begins?
Engineering transforms the design definition of a component into a solution that can actually be manufactured, taking into account from the outset the real conditions under which it will be produced.
At CAB, we use CATIA V5 for the modelling and design of parts, surfaces and assemblies. Activities may also include reverse engineering, metrology and the development of tooling required for production.
However, the key point is not simply the availability of the software.
A theoretically correct geometry must be analysed while taking into account the material, tolerances, tool accessibility, expected deformation, springback, manufacturing sequence, any heat or surface treatments, and the way in which the component will subsequently be assembled.
For example, in the case of a sheet metal formed part, the design must consider how the alloy will react to deformation and which reference points will remain available for subsequent manufacturing operations. In the case of a welded structure, fixture positioning and potential geometric variations caused by heat must also be evaluated.
The design of dies, fixtures, jigs and tooling therefore becomes part of the industrialisation of the component: it helps control positioning, ensure repeatability and connect the design with the actual requirements of the production departments.
Why Is the Manufacturing Sequence Critical to Tolerances and Final Quality?
The manufacturing sequence is critical because, in the production of a complex component, each stage can modify the geometric, dimensional or metallurgical conditions on which the following stage will operate.
Correctly determining when to perform forming, welding, CNC machining or a treatment is therefore not simply an organisational decision: it directly affects the ability to maintain tolerances and achieve the final result required by the design.
Consider, for example, a structure that must first be formed and then welded. The heat introduced during welding can generate distortions that make it necessary to perform certain machining operations only after joining. Conversely, specific surfaces or holes may need to be machined beforehand, while the component is still easier to access and position.
The same principle applies to heat treatments. Depending on the alloy and applicable specification, processes such as solution heat treatment, ageing or annealing can modify the metallurgical condition and dimensional stability of the part. Their position within the manufacturing cycle must therefore be evaluated together with the forming and machining operations.
Surface treatments must also be considered within the production sequence. Chemical conversion coatings, anodising, primers or technical coatings can affect functional surfaces, masking requirements, fits and final tolerances. Applying them at the wrong stage can make subsequent operations more difficult or even compromise them.
For this reason, at CAB, the manufacturing cycle is not defined starting from an individual machine or operation, but from the final result required from the component.
The objective is to establish a consistent sequence between engineering, manufacturing, special processes and assembly, so that each stage correctly prepares the component for the next one.
Which Supply Chain Issues Can Be Reduced Through a More Integrated Manufacturing Process?
In our experience, the most common issues do not arise solely from the complexity of individual manufacturing operations, but primarily from the handoffs between different suppliers.
When a component needs to pass through multiple companies for forming, CNC machining, welding, heat treatment, surface protection and assembly, the number of technical, logistical and documentation interfaces that need to be coordinated inevitably increases.
Every transfer requires planning, transportation, verification of the component’s condition, correct revision management and continuity of information. The more fragmented the manufacturing cycle becomes, the more points there are where delays, damage, documentation misalignment or different interpretations of specifications may arise.
This becomes particularly evident when a non-conformity occurs. If the part has passed through several facilities, identifying the stage at which a geometric deviation, distortion or surface issue originated may require the involvement of multiple parties and the review of records generated throughout the entire supply chain.
This is precisely where the CAB model can provide a practical advantage.
When multiple manufacturing operations are managed within the same production process, we can maintain greater continuity between engineering, manufacturing, special processes, inspection and assembly, reducing external handoffs and facilitating technical communication between the departments involved.
For us, however, vertical integration does not simply mean “doing everything in-house”. The value comes from the ability to coordinate the different stages correctly, maintain component traceability and respond more quickly when one manufacturing operation affects the next.
For this reason, when assessing a project, we consider not only the number of suppliers involved, but above all the number of critical interfaces that need to be managed in order to achieve the final result.
It is when these interactions increase that a more integrated manufacturing approach can become particularly effective.
How Are Forming, Machining and Welding Integrated into CAB’s Manufacturing Process?
Sheet metal processing and forming are among CAB’s long-standing core capabilities.
We primarily work with aluminium and aluminium alloys, steels, stainless steels and titanium, materials that behave differently during forming, machining, welding and treatment processes.
Forming requires an understanding of the actual behaviour of the alloy, rolling direction, bend radii, deformation and springback. The final result therefore depends not only on the availability of presses and dies, but also on defining the manufacturing cycle and tooling required to control geometry.
CNC machining can be used both to manufacture components directly from solid material and to machine parts that have previously been formed or welded.
The latter is particularly important in integrated projects, as it makes it possible to restore surfaces, reference features or holes to the required conditions after manufacturing operations that may have altered the geometry.
Welding introduces an additional variable. Localised melting generates heat and may cause distortion, meaning that tooling, welding sequence and subsequent manufacturing operations must be assessed together.
At CAB, these capabilities can be coordinated within the same manufacturing process, defining the sequence according to the component rather than treating forming, machining and welding as independent activities.
How Is Traceability Maintained When a Component Passes Through Multiple Manufacturing Stages?
At CAB, traceability follows the component throughout the entire manufacturing cycle, connecting material, drawing revision, completed operations, inspections and project documentation.
This makes it possible, at any time, to reconstruct the history of the part and verify which information and requirements were used during each manufacturing stage.
This is particularly important in aeronautical and aerospace production, where a documentation change, drawing revision or non-conformity must be traceable precisely to the affected component and to the operations already performed.
To support this process, we use ERP and MES systems, which help maintain visibility over project status and continuity of information throughout the different manufacturing stages.
When Does It Make Sense to Entrust a Component to a Vertically Integrated Industrial Partner?
Working with a vertically integrated industrial partner such as CAB becomes particularly useful when the component requires multiple closely interconnected manufacturing operations and the coordination between one stage and the next affects tolerances, quality, lead times and documentation.
Integrating the entire manufacturing cycle is not always necessary.
If the project requires a single, clearly defined operation, a specialist supplier may be the most suitable solution.
The value of integration becomes particularly evident when engineering, forming, CNC machining, welding, treatments and assembly need to be considered as parts of the same manufacturing process.
In these cases, before defining the scope of supply, it is useful to assess component complexity, critical tolerances, the number of processes involved, applicable specifications and the required level of control and traceability.
It is on this type of project that the CAB model finds its most complete application.
We can support an individual manufacturing stage or manage a broader process, connecting engineering, manufacturing, special processes and assembly, up to the production of finished components, structures and subassemblies.
The objective is not to concentrate the highest possible number of manufacturing operations, but to define the production cycle that is most appropriate for the component to be manufactured.
If you are evaluating the production of a complex component or would like to determine which stages could be managed within a single manufacturing process, you can contact the CAB team to share drawings, specifications and project requirements.
Article prepared under the supervision of CAB Costruzioni Aeronautiche Bertola
What is meant by a complex metal component?
A metal component can be considered complex when its geometry, materials, tolerances or number of required manufacturing processes demand the coordination of multiple production capabilities.
Complexity can therefore arise both from the shape of the part and from the manufacturing operations and inspections required to produce it.
Which materials does CAB work with?
CAB primarily works with aluminium and aluminium alloys, steels, stainless steels and titanium, which are used in the production of technical and structural components.
Can CAB also perform a single manufacturing operation?
Yes.
Production integration does not mean that every project must necessarily include all available manufacturing stages.
CAB can perform a single operation or manage a more complex manufacturing cycle depending on the customer’s requirements.
What is the difference between a finished component and a subassembly?
A finished component is an individual part that has completed all the required manufacturing operations and treatments.
A subassembly, on the other hand, consists of multiple components that have already been joined, inspected and prepared for subsequent integration into a larger structure or system.
What is the advantage of having engineering and manufacturing within the same process?
It allows manufacturability to be assessed from the earliest stages while taking into account materials, tooling, deformation, tolerances and subsequent manufacturing operations.
In this way, engineering decisions can be directly connected with actual manufacturing conditions.
Sources
CAB Costruzioni Aeronautiche Bertola, Corporate Website
https://www.cab-bertola.com/it/
CAB Costruzioni Aeronautiche Bertola, Engineering
https://www.cab-bertola.com/it/ingegneria/
CAB Costruzioni Aeronautiche Bertola, Technologies
https://www.cab-bertola.com/it/tecnologie/
CAB Costruzioni Aeronautiche Bertola, Special Processes
https://www.cab-bertola.com/it/processi-speciali/
CAB Costruzioni Aeronautiche Bertola, Assemblies
https://www.cab-bertola.com/it/assemblaggi/
International Aerospace Quality Group, Supply Chain Management Handbook
https://scmh.iaqg.org/
National Institute of Standards and Technology, Digital Thread for Manufacturing
https://www.nist.gov/programs-projects/digital-thread-manufacturing
National Institute of Standards and Technology, Defining Requirements for Integrating Information Between Design, Manufacturing and Inspection
https://www.nist.gov/publications/defining-requirements-integrating-information-between-design-manufacturing-and