Aero Gear expands in Windsor, Connecticut

Commercial and military aircraft gearbox manufacturer Aero Gear in Windsor, Connecticut, has completed a 24,000ft² expansion. As a key player in the state’s aerospace industry for more than 35 years, it has contributed to the success of companies such as Pratt & Whitney, Sikorsky, and GE.

“In trying to meet the increased orders from our customers, it became obvious that additional people and machines were necessary, and the only way to accommodate this was through enlarging our physical space,” explains Doug Rose, Aero Gear’s founder. “Although we have clients around the world, the expansion demonstrates that we are committed to the long-haul in Connecticut.”

Rose points to the simultaneous growth of the commercial and military defense industries and their need for assembled gearboxes as a prime catalyst for increased production. Aero Gear makes the power drive gear systems for fixed and rotary wing aircraft. The mechanisms require the highest quality precision engineering and manufacturing.

Aero Gear’s proprietary Flow Line concept is based on providing the best quality, shortest lead time, and reasonable cost by eliminating waste in the process. Most of the Lean Flow processing is conducted within a modern, climate controlled 69,000ft² facility, including gear processing capabilities such as low-pressure vacuum carburized and hardened heat treatment, super finishing, balancing, and non-destructive testing. The new space will have a total of 100,000ft² with 175 employees, plus provide a lobby, conference room, offices, and manufacturing space for several new programs.

Aero Gear’s expertise was recently awarded the recognition of Elite Supplier from longtime customer, Lockheed Martin Sikorsky Aircraft. This is the second year in a row that Lockheed has chosen the company for the award that honors consistency, reliability, and resourcefulness. Aero Gear’s product development and support service also earned United Technologies Corp.’s rank of Gold Supplier for a second year.

Connecticut Gov. Dannel Malloy and other political and business leaders will celebrate the grand opening of Aero Gear’s new space at a ceremony on Tuesday, June 12, 2018.

Aero Gear also is creating skilled employees through its training program. The company actively works with state community colleges to customize a curriculum to put graduates in the field immediately after graduation.