Aerospace and Aviation

Mixing Solutions for Aerospace and Aviation Manufacturing Challenges

Aerospace and aviation manufacturers work with some of the most demanding materials in modern manufacturing. Epoxy compounds, carbon fiber reinforced resins, silicone sealants, syntactic foams and thermal interface materials are engineered for extreme operating conditions with no margin for error.

They are also among the most difficult to process. High viscosities, shear and temperature sensitivity, air entrapment and narrow processing windows all require tight control at every stage of production.

Aerospace and aviation manufacturers also operate under the most rigorous quality and regulatory standards in any industry. AS9100 certification and NADCAP process approvals require mixing equipment and controls that support documented, validated, traceable and repeatable procedures at every step of the process.

Provides necessary data for AS9100 and NADCAP compliance – Mixing equipment and controls must support these requirements at every step of the production process.

Why Mixing Precision is a Safety Requirement

In aerospace and aviation, an ineffective mixing process can pose catastrophic safety risks. Inadequate dispersions can weaken structural bonds. Entrapped air creates voids that reduce load bearing capacity and durability under repeated stress. Inconstant shear leads to uneven curing and unpredictable material behavior. Poor temperature control can push formulations past their processing window.

Getting the mixing process right is not an option, it is a safety necessity.

These risks are amplified by the extreme operation environments aerospace materials must withstand:

• Wide temperature differences and rapid thermal cycling from sub-zero at altitude to high heat near engines
• Continuous vibration and mechanical fatigue during flight operations
• Pressure differentials across altitude changes and sealed systems
• Exposure to fuels, hydraulic fluids, and aggressive chemicals
• High mechanical loads and repeated stress cycles over long service lifetimes

Talk to a ROSS Mixing Expert

Every aerospace and aviation mixing application has its own set of requirements. Since 1842, ROSS Mixers have developed the engineering and manufacturing expertise to support and advance development in the aerospace industry. Our sales team and engineers partner with manufacturers to understand the materials, the process goals, and production environment before recommending a solution. Whether you are scaling up a new formulation, validating a process or looking to improve an existing process, we can help.

Contact us to discuss your application or request a mixing trial at our Test & Development Center in Hauppauge, NY.

ROSS Mixing Solutions for Aerospace & Aviation Applications

Since 1842, ROSS Mixers have developed the engineering and manufacturing expertise that continues to support the aerospace industry.

The quality of the finished product depends on the mixing process. ROSS has partnered with aerospace and aviation manufacturers to develop mixing systems engineered for these challenges.

Double Planetary Mixers: Engineered for high-viscosity compounds including epoxies, structural adhesives, sealants and propellant formulations. Also used for low shear through mixing of insulating compounds

High Shear Mixers: Used for emulsification, solids wet-out and particle dispersion in advanced aerospace material formulations

Vacuum Mixing Systems: Eliminate entrapped air and voids in structural, thermal and syntactic foam materials where strength and durability are safety requirements

Advanced Controls: Data acquisition and process control systems that support batch traceability, repeatability and regulatory compliance

Formulations ROSS Mixers Are Engineered For

ROSS Mixing equipment is used across a broad range of aerospace and aviation applications, including:

Structural adhesive mixing: Bonding compounds for airframe assemblies, control surfaces and composite structures where joint integrity is a structural requirement.

Carbon fiber composite resins and casting materials: Epoxy and resin systems used for primary and secondary aircraft structures.

Syntactic foams and insulations: Lightweight void-fill and buoyancy materials used in aerospace housings, fairings and thermal protection systems.

Thermal interface materials: Compounds used to manage heat dissipation in avionics, power electronics and propulsion systems.

Propellant and energetic material formulations: High-viscosity, shear-sensitive compounds requiring precise temperature control and vacuum mixing under strict safety protocols.

Sealants and potting compounds: Silicone and polyurethane systems used for environmental sealing, vibration damping and component encapsulation.