Business Details
Aerospace Ducting Systems & Composite Manufacturing
Senior Aerospace Bwt has established itself as a leader in the design and manufacture of advanced aerospace ducting systems and composite components. With decades of experience serving commercial, regional, and defence aircraft sectors, we combine technical expertise with cutting-edge innovation to deliver lightweight, high-performance solutions. Our dedicated engineering teams and state-of-the-art facilities in Macclesfield, UK, enable rigorous testing and development of products that meet stringent industry standards. We prioritise operational excellence, investing in additive manufacturing and proprietary thermoplastic composite technologies to reduce lead times and enhance aircraft efficiency. Our long-standing partnerships with global aerospace leaders underscore our commitment to quality, reliability, and customer satisfaction.By maintaining strict manufacturing controls and focusing on sustainable practices, we ensure every product meets exacting specifications while addressing the evolving needs of modern aviation. Our dedication to innovation is exemplified by our adoption of 3D printing technologies, which streamline prototyping and production processes. With over 10,000m of manufacturing space and a focus on employee expertise, we continue to push the boundaries of what is possible in aerospace engineering. Our values of integrity, collaboration, and continuous improvement drive us to exceed client expectations and contribute to the advancement of the industry.
Services
Thermoplastic Composite Ducting
Elastomeric Flexible Ducting
Noise Attenuation Ducting
Preformed Composites
Additive Manufacturing
Highlights and features
- We have decades of experience in aerospace ducting system design and certification.
- Our proprietary thermoplastic composite technology reduces weight and improves durability.
- We operate a dedicated 10,000m facility with advanced testing capabilities.
- Our additive manufacturing centre ensures rapid prototyping and cost-effective production.
- We maintain strict compliance with international aerospace standards (RTCA/DO-160, ABD0031).
Associations and certifications
- EASA Part 21G
- ASTM E 882
- FAR25.853(a)
- RTCA/DO-160G
Services
Thermoplastic Composite Ducting
Our thermoplastic composite ducting systems utilise proprietary ultra-lightweight reinforced materials to deliver smooth bore solutions for aerospace applications. These semi-rigid ducts maintain performance integrity while enabling complex geometries, optimising space usage in aircraft systems. Designed for temperatures between -65C and 180C, they offer excellent durability, puncture resistance, and compliance with RTCA/DO-160 FST standards.
Elastomeric Flexible Ducting
Elastomeric flexible ducting solutions cater to low and high-temperature applications using urethane/nylon or silicone-based constructions. Available in standard or custom profiles, these lightweight, durable ducts incorporate transitions and end-interface connections. They operate within -65C to 200C and meet RTCA/DO-160 material compatibility requirements while offering ease of installation.
Noise Attenuation Ducting
Noise attenuation ducting systems combine flexible and semi-rigid constructions to reduce acoustic emissions in aerospace environments. Manufactured with acoustic insulation and available in diameters from 0.75" to 6", these lightweight ducts (490g/m at 2" diameter) maintain thermal performance while minimising pressure loss and meeting ABD0031 standards.
Preformed Composites
Preformed composites utilise our proprietary RT2i thermoplastic process to create 3D near-net-shape components with integrated features like flanges and stubs. Using materials such as PEI Ultem 9085 and Kevlar reinforcement, this technology eliminates autoclave requirements while offering scalability, material waste reduction, and enhanced reliability compared to traditional thermoset methods.
Additive Manufacturing
Additive manufacturing capabilities include FDM technology using aerospace-approved Ultem 9085 resins and binder jet 3D printers for rapid prototyping. This enables cost-effective production of complex components, tooling, and non-flight parts while supporting lean manufacturing processes and accelerating product development cycles through model-to-manufacture methodologies.
Questions
What aerospace sectors does Senior Aerospace Bwt serve?
We serve commercial and regional aircraft, defence aerospace, business jets, rotorcraft, automotive, and medical sectors with custom-engineered ducting systems and composite components.
Where is Senior Aerospace Bwt located?
Our headquarters and primary manufacturing facility is located at Adlington Business Park, Adlington, Macclesfield, Cheshire SK10 4NL, UK.
What materials do you use in your ducting systems?
We use proprietary thermoplastic composites, elastomeric materials, and reinforced fibres including PEI Ultem 9085, PC Lexan FST 9705, glass, and Kevlar to meet aerospace performance requirements.
Do you offer additive manufacturing services?
Yes, we operate industrial-grade Stratasys Fortus 450mc 3D printers using FDM technology with aerospace-approved materials for prototyping and production components.
Are career opportunities available at Senior Aerospace Bwt?
Yes, we regularly recruit for technical and engineering roles at our Macclesfield facility. Visit our careers page to explore current openings in the aerospace industry.
