Aurora Flight Science - Bridgeport, WV

Aurora Flight Sciences’ corporate headquarters and engineering center is located in Manassas, VA with aerostuctures production facilities in Bridgeport, WV at the North Central West Virginia Airport (CKB) and in Columbus, MS. The firm’s research and development center is located in Cambridge, MA.

Aurora Technicians put the final touches on a Global Hawk V-Tail before shipment.

Aurora has three primary business areas: aerostructures, science UASs and tactical UASs. The leading small business in the UAS industry, Aurora Flight Sciences’ major customers include the National Aeronautics and Space Administration, the Defense Advanced Research Projects Agency, the U.S. Air Force, Northrop Grumman, Boeing, Raytheon and Sikorsky. Having established an aerostructures manufacturing capability in 2000, Aurora Flight Sciences is today a major supplier to the Global Hawk UAS program, building the primary composite flight structures.

Founded in 1994, the company’s Bridgeport, WV manufacturing facilities are comprised of almost 100,000 square feet of shop area designed specifically for the manufacture of precision composite (non-metallic and metallic) and sheet metal components.

	Aurora technicians prepare the Global Hawk forward nacelle for bonding.

The Bridgeport operation includes a 42,000 square foot composites facility, which includes a clean room, autoclaves and extensive nondestructive inspection (NDI) capabilities, including large component ultrasonic C-scan capability. Aurora’s 50,000 square foot metals, composites, and tooling facility includes an extensive machine shop with a CNC router and water-jet cutter.

Aurora’s membership in the Mid Atlantic Aerospace Complex (MAAC) is an important component in the company’s long-term aerospace mission, as attested to by Aurora, West Virginia, General Manager Ron Richman when he says, “We maintain a diverse work force and are actively pursuing international markets. The Aerospace Complex is a great way to develop strategic partnerships with organizations whose capabilities and missions are complementary to our own.”

Aurora Flight Sciences capabilities include a 10 axis ultrasonic through transmission inspection system.

The Bridgeport facilities are able to manufacture complex aerospace composite structures, both primary and secondary, laminate and sandwich construction, prepreg and wet lay-up processing.

It is experienced with a wide range of materials, including carbon fiber epoxy, fiberglass epoxy, honeycomb core and metal bonded composites. The West Virginia operation handles complex vehicle assemblies, including flight control structures.

	Aurora personnel run through final fit up of the Global Hawk forward nacelle before paint.

The manufacturing site includes:

• A 10,000 square foot clean room for composite lay-up
• A 2,000 square foot lay-up room for prepreg and wet lay-up
• Autoclaves with digital and analog control
• PC data acquisition with bar code product scanning
• Multiple bonding ovens
• Heat treat oven
• Ultrasonic C-scan NDI
• Coordinate Measuring Machine (CMM)
• Eddy current, Rockwell hardness, and dye penetrant inspection

To ensure repeatable, reliable production, Aurora maintains multiple quality certifications including: ISO 9001:2000, AS 9100 and NADCAP certifications in welding/brazing, heat treat, nondestructive testing, engineering design, composite manufacturing and chemical processing.

Aurora’s 10,000 sq.ft. Clean room for composite manufacturing.		Composite material is nested and cut using state of the art software and a computer controlled Gerber ply cutter.

In addition to its quality certifications, Aurora maintains a robust, MRP/ERP system-based program management infrastructure.

The company’s commitment to process-driven manufacturing and conscientious program management means that work contracted to Aurora is on time, on budget and within specifications every time.

Aurora’s Bridgeport WV Manufacturing team!		Aurora technicians accomplish the gap check and final fit up for the Global Hawk.

Primary Contact Person for Inquiries

Ron Richman
General Manager
Aurora Flight Sciences Corporation
3000 East Benedum Industrial Drive
Bridgeport, WV 26330
Ph: (304) 842-8100
Fax: (304) 842-8116
E-mail: rrichman@aurora.aero

URL: http://www.aurora.aero