At Exemplar, we follow a lean, standardized manufacturing process to ensure each component meets exacting customer specifications and quality standards. From parts preparation to final inspection, every stage is optimized for efficiency, accuracy, and compliance.
Each assembly phase—fuselage, wings, and fuel tanks—follows detailed build diagrams, rigorous quality checks, and gate inspections to maintain structural integrity and process consistency. Our focus on continuous improvement and waste reduction ensures reliable, high-performance assemblies delivered on time and to spec.
Explore our streamlined processes below.
Parts Preparation Process
All customer-supplied parts arrive ready for assembly. To ensure full compliance with customer specifications and quality standards, each part undergoes a standardized preparation process prior to final assembly.
This process includes deburring to remove plastic laminates and smooth edges, followed by thorough scrubbing and drying to ensure a clean surface for painting. After cleaning, parts are transferred to the painting booth for priming, which serves as a protective layer to prevent corrosion.
Once priming is complete, the parts are fully prepared and ready for the assembly phase.
Sub-Assembly Process (Fuselage)
The sub-assembly process for the fuselage begins with the assembly of small parts using a riveting gun, following the detailed assembly diagram. This is followed by the assembly of the center section and the firewall.
Two major components—the forward center section and the aft center section—are then joined together. Before the assembly proceeds to the next station, our Quality Control team conducts a gate inspection using a process checklist to ensure compliance with all assembly specifications.
Structural Assembly Process (Fuselage)
In this phase, the partially sub-assembled fuselage kit is carefully positioned in a jig to facilitate precise alignment and integration. The process involves laying out and installing the top, bottom, and side skins, along with other components as specified in the assembly diagram. This meticulous approach ensures the structural integrity and aerodynamic performance of the fuselage.
Prior to transitioning to the next assembly phase, Quality Control personnel conduct a gate inspection. Utilizing a comprehensive process checklist, they verify that all assembly specifications have been met, ensuring compliance with stringent quality standards.
Finishing Section (Fuselage)
In this phase, the fuselage assembly kit is carefully removed from the jig and transferred to the finishing area for final processing. Components not yet integrated into the structural assembly are completed in this section, following detailed assembly diagrams.
Quality control personnel conduct a gate inspection using a comprehensive process checklist to verify compliance with design specifications. Upon completion, all documentation is consolidated and filed appropriately. Before shipping, the Buy-off Inspector performs a final inspection to verify compliance with Quality Assurance standards.
Wings Assembly Process
In this phase, the wing's skeletal structure is meticulously assembled to form a robust framework. This includes the precise installation of the main spar and ribs using a riveting gun, ensuring structural integrity and alignment.
Quality control personnel conduct a thorough inspection using a comprehensive process checklist to verify compliance with design specifications. Following the gate inspection, the wing skins are carefully laid out and prepared for subsequent installation.
This structured approach guarantees that each wing assembly meets our stringent quality standards before proceeding to the next phase.
Tank Assembly Process
In this phase, the fuel tank is meticulously assembled to ensure structural integrity and leak-free performance. The process begins with the precise layout of components, followed by the installation of stiffeners and inner ribs to reinforce the tank's structure. The assembly concludes with the installation of closing baffles, ensuring the tank's compartments are securely sealed.
A critical step in this process is the application of sealant to all joints and seams. This sealant not only prevents fuel leaks but also enhances the tank's resistance to corrosion and environmental factors.
Before proceeding to leak testing, the assembled fuel tank undergoes a gate inspection by Quality Control personnel. Using a comprehensive process checklist, they verify that all assembly steps have been completed correctly and that the tank meets all quality standards.
Flight Control Assembly Process
In this phase, primary flight control surfaces—including ailerons, flaps, flaperons, vertical and horizontal stabilizers —are meticulously assembled. The process encompasses sub-assembly, skin riveting, sealing, and final finishing.
Quality Control personnel conduct a gate inspection using a comprehensive process checklist to ensure compliance with all specifications.