In the domain of aerospace manufacturing, precision, efficiency, and compliance are all that matter. For Aero Forge Industries – one of the largest manufacturers of jet engine components in Bangalore, India – a production bottleneck was a risk to their ability to keep up with soaring demand for complex turbine blades. By implementing CNC Tilting Rotary Tables by Kuvam Technologies, Aero Forge was able to reduce total cycle times by 44 %, cut scrap rates by 60 %, and create annual savings of Rs. 625,000. In this blog, we will look at their case study, the challenge, the solution, and what aerospace manufacturers can take away to improve their operations.
The Challenge: Bottlenecks in Turbine Blade Production
Aero Forge Industries manufactures turbine blades made from titanium and nickel-based superalloys. Turbine blades have very rigorous tolerances and therefore complex 5-axis geometries. Aero Forge was following high demand in 2024 with orders from key global customers like GE Aviation and Rolls-Royce, requesting a 30% increase in production; however, their legacy 3-axis vertical machining centres (VMCs) were a significant barrier to achieving this growth, for several reasons:
- Long cycle times: It was taking up to 12 manual setups to machine the undercuts and curved surfaces on each blade during the machining process. This resulted in an average cycle time of 45 minutes per part, thus allowing a maximum daily production rate of 120 blades over two shifts.
- Precision issues: With each setup and manual repositioning, there were inaccuracies in the machining process of up to ±0.02 mm deviation as compared to the CAD file, resulting in a scrap rate of about 15% and approximately Rs. 150,000 in rework costs annually.
- Compliance risks: The number of manual setup operations increased the likelihood of human error, increasing the non-conformance reports by 25%, all of which jeopardised the AS9100 certification Aero Forge Industries needed following a FAA audit.
- Rising costs: The additional labour time and downtime of the machines increased the per-part cost by approximately 20%, causing waste of Rs. 2.5 million in inefficiencies.
As Aero Forge’s Production Manager, Rajesh Kumar, put it: “Our old process was a bottleneck. Every extra setup slowed us down and risked our quality standards. We needed a solution that could upgrade our existing machines without breaking the bank.”
The Solution: Kuvam’s CNC Tilting Rotary Tables
After evaluating several vendors, Aero Forge chose Kuvam Technologies’ Model KXTT 215 CNC Tilting Rotary Table, a compact, high-precision 4th/5th-axis solution designed for seamless integration with standard VMCs. Key features include:
- Dual-axis tilting (±110°) allows access to complex geometries at multiple angles, minimising setups for efficient workpiece completion.
- Direct-drive servo motors ensure backlash-free operation with a repeatability of 0.002 mm.
- 215 mm table diameter provides a compact footprint that fits perfectly with Aero Forge’s Haas VF-2 machines, requiring minimal modifications.
- Advanced CAD/CAM integration with Mastercam enables real-time error correction to maintain production accuracy.
Kuvam’s India-based manufacturing enabled delivery of the KXTT 215 in under 6 weeks, along with localised support—far superior to overseas options with extended lead times. Priced at Rs. 25 lakhs per unit (including installation), it’s a cost-effective upgrade compared to full 5-axis machine replacements exceeding Rs. 200 lakhs.
Implementation: A Seamless Transition to 5-Axis Efficiency
Kuvam Technologies followed a streamlined, customer-focused approach for deploying the KXTT 215 CNC Tilting Rotary Table, emphasising simulation and on-site execution to ensure minimal disruption to Aero Forge’s operations:
- Simulation of Workpiece through 3D Software by R&D Team: Kuvam’s R&D team utilised advanced 3D software, such as SolidWorks, to simulate turbine blade workpieces on the KXTT 215. This virtual modelling analysed complex geometries, optimised tilting angles (±110°), and predicted integration with Aero Forge’s Haas VF-2 VMCs, forecasting a 40% cycle time reduction while validating precision parameters like 0.002 mm repeatability.
- Installation and Proofing at Customer Site and Training: At Aero Forge’s facility, Kuvam engineers handled full installation of the KXTT 215 units, including mounting and machine controller integration. Prove out involved running test cycles on sample blades to confirm performance, followed by comprehensive on-site training for operators and programmers. Sessions covered G-code programming for multi-axis operations, safety protocols, and maintenance, empowering the team to achieve seamless production within days. Total rollout ensured zero downtime, with 24/7 support available..
Results: Game-Changing ROI and Compliance Gains
The impact was immediate and measurable, tracked through Aero Forge’s ERP system:
| Metric | Before | After | Improvement |
| Cycle Time per Blade | 45 minutes | 25 minutes | 44% reduction |
| Daily Throughput | 120 blades | 174 blades | 45% increase |
| Scrap Rate | 15% | 6% | 60% decrease |
| Annual Cost Savings | N/A | Rs. 625,000 | 25% per-unit cut |
| AS9100 Compliance Score | 85% (audit baseline) | 98% (post-audit) | 15% uplift |
The Rs. 180,000 investment delivered Rs. 750,000 in first-year savings, achieving ROI in just 3.5 months. By Q3 2025, Aero Forge surpassed its 30% output goal by 12%, securing a Rs. 5 million follow-on contract with a major OEM. The improved precision also eliminated Rs. 100,000 in potential audit fines.
Rajesh Kumar summed it up: “Kuvam’s tilting rotary tables turned our shop floor into a powerhouse. The precision we’ve achieved isn’t just about numbers—it’s the difference between meeting deadlines and losing contracts. Their tech paid for itself before we even finished the pilot.”
Why Kuvam’s Technology Made the Difference
Kuvam’s CNC Tilting Rotary Tables were uniquely suited for aerospace’s zero-failure demands. The direct-drive system eliminated gear backlash, critical for machining thermally sensitive alloys. The tilting capability slashed setups from 12 to 2 per blade, directly solving Aero Forge’s multi-axis woes. Plus, Kuvam’s modular design and local manufacturing—reducing import duties by 18%—ensured scalability without supply chain delays. Without this solution, Aero Forge would have faced costly machine replacements or prolonged inefficiencies, proving how targeted CNC upgrades can bridge legacy systems to modern standards.
Takeaways for Aerospace Manufacturers
For aerospace manufacturers facing similar production challenges, here’s how to replicate Aero Forge’s success:
- Audit Your Process: Map cycle times and tolerance deviations to pinpoint inefficiencies. Aim for solutions offering at least 30% gains.
- Choose Compatible Tech: opt for rotary tables that integrate with existing VMCs to avoid hefty capital investments. Validate with simulations first.
- Partner Locally: Collaborate with vendors like Kuvam for expedited delivery and customized support, particularly in regulated industries.
- Track Holistic Metrics: Measure compliance and quality alongside output—precision can unlock premium contracts and audit savings.
- Pilot Before Scaling: Test on a single line to build confidence, then expand with data-driven tweaks.
Elevate Your Aerospace Manufacturing with Kuvam
Aero Forge’s narrative illustrates that utilising superior technologies can flip challenges into opportunities. By utilising Kuvam’s CNC Tilting Rotary Tables, manufacturers can increase efficiencies, drive compliance, and remain competitive in a challenging industry. Ready to optimise your production? Visit kuvamtechnologies.com to explore their efficiencies and contact their team to schedule a consultation.
For more information, contact Kuvam Technologies at +91 9560500384 or email us at marketing@kuvamtechnologies.com
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