Nasmyth Metallics Bullwell (Bullwell) has delivered a major component for an aircraft in-flight refuelling (IFR) system to BAE Systems.

The IFR coupling was categorised as a critical risk factor, which could delay delivery of BAE Systems’ programme if supply consistency could not be achieved.

BAE Systems explored various options and in April 2015, Bullwell started work on delivering the coupling as a machine-from-solid component using a complex five-axis machining.

"Seeing such a successful outcome acknowledged with a tangible award is immensely satisfying and encouraging for us.”

This approach provides complete consistency and accuracy, as well as eliminates all the issues related to the casting of the part.

After having designed, developed, tested and refined the solution, Bullwell delivered its first production unit IFR coupling to BAE Systems in December 2015. 

Since then, Bullwell owner Nasmyth Group has continued to consistently deliver machined components. This has made the IFR coupling no longer a production issue for the BAE Systems programme.

Nasmyth Group UK chief operating officer Simon Beech attended BAE Systems’ Chairman’s Award scheme to celebrate the delivery of this component.

Beech said: “Nasmyth Metallics demonstrates our engineering skills, expertise and commitment to problem solving.

“I am delighted that our team’s deep understanding of BAE Systems’ position and challenges has been recognised as a critical part of the Hawk programme’s success. Nasmyth Group continually invests in delivering innovations in engineering technology, processes and design which meet our customers’ requirements. Seeing such a successful outcome acknowledged with a tangible award is immensely satisfying and encouraging for us.”

The IFR coupling project was nominated in the Exceeding Customer Expectation category and the BAE Systems Procurement team that managed the Nasmyth Group project was selected from 280 nominations. 

The BAE Systems Chairman’s Award was presented by BAE Systems vice-president of procurement and air frame supply chain director Steve Vandersteen.