Aerospace

Propulsion systems to structures, rotorcraft to rockets, sea level to sub-orbital, GEO, and beyond.

When it comes to the aerospace sector, Roush’s roots run deep. Roush provides the aerospace industry a single-source product commercialization solution for developing everything from advanced cryogenic propulsion systems for use in non-terrestrial environments through design and construction of full-scale aircraft models.

From space travel and the development of  VTOLs to flight simulators, military aircraft, and beyond, we apply decades of product commercialization expertise to bring customers’ products to market quickly and efficiently.

Because of Jack Roush’s decades-long love affair with vintage warbirds, we also reverse engineer and apply modern manufacturing, design, and materials expertise to vintage aircraft parts.

The sky is not the limit when it comes to serving our customers’ needs.

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Aerospace Overview

Customer Testimonials

“I deal with a lot of companies for the purposes of marketing ideas, concepts and actual products and among those companies, Roush is a standout. They are exceptional at what they do in the full-scale mockup space. Workmanship and engineering expertise are exceptional. Their ability to meet demanding schedules is also noteworthy. The best part of working with Roush is their professionalism, discretion and their ability to produce exceptional results time after time.”

– Frank Lazzara, Director, Sales & Strategy, Bell Textron

“The fusion of aerospace and automotive high technology created by Roush has led to a pace of advancement that is simply unmatched. The team at Roush has rapidly integrated innovative component and system hardware and software elements to meet our novel needs at affordable costs.”

– Advanced Programs Team Member, United Launch Alliance

Success Stories

Bell Helicopter

Our Services

Design

Roush's Creative Services group takes to the sky, developing concepts and models for the expanding air mobility space to bring product ideas to life.

Class A Surface Development
Ideation Sketches
Theme Design
Studio Engineering
Digital Design
3D Model Development
Class A Surface Development
Proof of Concept Demonstrators

Concept Sketches for Air Taxi

Engineering

Roush’s engineering capabilities range from reverse engineering and analysis of components to full-property development projects, with expertise in advanced disciplines. We focus on the use of high- performance materials such as composites and the optimization of structures using computational aided engineering approaches with production enabled by advanced manufacturing methods such as additive manufacturing to address the critical issues of light-weighting and strength.

Modeling Simulation
Technology Integration
Propulsion Systems
Energy Storage Conversion
Body Structures
Noise Vibration
Electrical Systems
Thermal Systems
Controls Software

United Launch Alliance Integrated Vehicle Fluid Technology Development

Prototyping

Utilizing our on-site design team, engineering support, and model development services, Roush transforms design ideas into finished products that showcase our customers’ innovative aerospace products. Recent aerospace prototype activities include development of full-scale non-flight models used to support marketing activities, full-size models of variant units, and simulators used for flight training exercises such as refueling.

Full size/scaled Demonstrator Development
Graphic Services
Metal Fabrication
Rapid Prototyping
Advanced Composites
Wiring & Electronics
Trim Services
Custom Painting
Scanning

Scale Model of Prototype Helicopter

Testing

Roush offers aerospace customers a comprehensive array of testing activities. We apply CAE expertise to creating FEA models for validation and performing structural and torsional analysis of components and assemblies, which greatly reduces the cost and time required for product development activities.

Design and Build of Test Fixtures
Structural Analysis and Load Testing
Material Testing
Shaker Testing
Propulsion System Development

Helicopter Door Stress Analysis

Manufacturing

Roush provides the aerospace industry with extensive billet, cast and forged machining support and the fabrication of welded components. Custom-tailored work cells provide machining, assembly, and inspection operations – an efficient alternative for service runs, aircraft/marine components, and more. Our manufacturing support in the aerospace sector also includes additive manufacturing, advanced composite components, and specialized NVH products such as constrained layer damping patches for a noise control in commercial aircraft.

Flight Simulator Design & Hardware Build
Fixture Development, Design & Build
Additive Manufacturing
Assembly
Tooling
Machining
Welding

Machining of Trunnion Fitting

Certifications

IPC/WHMA-A-620 certification: prescribes practices and requirements for the manufacture of cable, wire and harness assemblies.
IPC-J-STD-001GS space addendum certification: signals that Roush meets the manufacturing requirements for wiring harnesses that must survive the vibrations and environments associated with space travel.
We are an approved FAA Repair Station (J23Rs73Y) and have an approved Inspection System for the manufacture of PMA components.
Our staff of engineers, scientists, technicians, and consultant FAA DER offer turnkey solutions for repair or complete ‘PMA Development’ requirements.
AS9100 expected 2022