Magellan Aerospace products

Magellan manufactures complex aeroengine frames for both the hot and cold engine modules. These products are manufactured from a combination of castings, forgings, and sheet metal, and may be made from titanium, nickel based alloys, or light alloys. They also are assembled fully or in part in our state-of-the-art facilities. Precision tolerance machining ensures that frames are produced to the industry’s most exacting standards. Special processes such as plating, thermal spray, and painting are performed, along with special cleaning processes with particulate filtration, to provide optimal endurance in extreme operating conditions.

Our compressor discs and cases undergo tight tolerance machining, including precision broaching, specialized processing and non-destructive testing (NDT). Complex processes ensure optimal product integrity through a combination of welding, fabrication, mechanical assembly, and intensive in-process inspection. Machined or cast, bearing housings, and other oil wetted products are subjected to close tolerance machining and special cleaning processes with particulate filtration.

Magellan manufactures a variety of frames and cases for use in the engine hot section. They are typically nickel-based alloys manufactured from casting, forging, bar, and sheet metal. We are known for producing high quality details and large complex assemblies.

Controlled broaching is a unique and key element in Magellan’s manufacture of turbine components, which require extremely tight tolerances with zero surface anomalies. We also offer maintenance solutions to our customers worldwide with several proprietary hot section repairs that produce higher performance and extended life. 

Magellan designs and manufactures metallic laser welded and resistance welded honeycomb using stable and repeatable processes and has unique attributes for higher temperature applications where glued honeycomb structures cannot perform. The products are typically produced in materials suitable for higher temperatures such as titanium, Inconel, stainless steel, and exotic alloys where strength and temperature are both key design considerations.

One of the most popular sounding rockets ever built, the Magellan-designed family of Black Brants have played a leading role in scientific exploration since 1962. More than 1,000 Black Brants have been launched with a vehicle success rate above 98%. Designed and developed at Magellan Aerospace, Black Brants are used as a single or multi-stage vehicle for placing scientific payloads into space or as a ballistic missile target. The most reliable, cost-effective and available sounding rocket in use today, they are continuously updated with new technology to meet NASA’s changing needs: up to 20 minutes of time for microgravity experiments, auroral studies, deep space observations, and other extraterrestrial research.

Designed and developed by Magellan in the 1980s for the CL-289 reconnaissance drone, more than 3,500 CL-89 and CL-289 booster motors were manufactured for the German and French armed forces. Exceptionally reliable, over 2,000 motors were delivered for military training and have been used during NATO operations since the 1990s without a single reported failure.

In 2009, Magellan was contracted by the US Army to deliver multiple batches of MQM-107 RATO booster motors. The technology behind the CL-289 booster motor was adapted, with electrical and mechanical interface modifications, to develop the MQM-107 for compatibility with the MQM-107 Aerial Target Drone.

Ingenuity and innovation have established Magellan Aerospace as a global leader in rocket design and development. With more than 800,000 rocket motors produced for 15 customers worldwide, Magellan’s CRV7 rocket weapon system has become the leading air-to-ground unguided 2.75-inch (70mm) rocket system available today. Optimized for two very different flight environments, the C15 came first for use from fixed wing aircraft, followed by the C17 for rotary wing platforms. The power behind the CRV7 is the propellant. CRV7 is longer range, faster time to target, and superior accuracy. The cost-effective CRV7 system includes HTPB composite propellant rocket motors, launchers, and various training and operational warheads to meet mission objectives.