Assembly (wip) | Portsmouth Aviation

At Portsmouth Aviation, our dedicated and highly trained fitters take pride in delivering outstanding quality across complex mechanical and electrical assembly projects, ensuring every customer order, whether large-scale production or smaller bespoke work, meets rigorous industry and quality standards.

Mechanical and Electrical Assembly

Portsmouth Aviation is recognised for delivering highly precise mechanical and electrical assembly services for complex, high-specification engineering applications. As an apprenticeship-focused organisation, we develop highly skilled technicians and mechanical fitters through expert training delivered by experienced industry professionals.

Our team is proficient in a wide range of assembly disciplines, including multipin soldering, crimping, continuity and functional testing, as well as the manufacture of high-integrity connectors and wiring looms. Working across both bespoke, low-volume assemblies and high-rate production programmes, we apply the highest levels of precision, care, and attention to detail to ensure customer satisfaction.

All work is carried out using approved materials, tooling, and controlled processes to guarantee reliability, repeatability, and full compliance with customer and industry requirements. Our strong focus on workmanship, inspection, and quality assurance ensures electrically and mechanically robust assemblies, supporting consistent quality performance and on-time delivery.

State-of-the-art tooling and processes

We utilise state-of-the-art tooling and processes to deliver consistent, efficient, and repeatable results across all assembly operations. Our use of advanced equipment and modern manufacturing techniques ensures high levels of accuracy and control in both low-volume and high-rate production environments.

This includes the design and manufacture of bespoke jigs and fixtures to support complex assemblies where precision is critical. These tools help improve build consistency, reduce variation, and enhance overall quality.

All tooling and processes are developed in line with strict quality standards, ensuring compliance with customer and industry requirements, while supporting continuous improvement across our operations.

Installation of Rivets and Fasteners

We are leading specialists in the installation and removal of all aerospace-approved rivet types, including solid, blind (pop), and tubular rivets, carried out in accordance with aerospace, aircraft, and defence industry standards. Our technicians are highly experienced in working with a wide range of aerospace fastener systems, including Jo-Bolts, Hi-Lok fasteners, Rivnuts, and Dzus fasteners, ensuring correct selection, installation, and removal to meet stringent quality, structural, and airworthiness requirements. All work is performed with a strong focus on precision, repeatability, and compliance, supporting both production and maintenance-related assembly operations.

Helicoiling

At Portsmouth Aviation, our highly trained fitters possess extensive knowledge and experience in all aspects of threaded insert installation and removal. We have recently invested in advanced automated Helicoiling equipment, ensuring each insert is installed accurately and consistently to the correct specification while supporting high-rate production requirements. This capability allows us to meet demanding customer schedules without compromising quality. Our expertise covers a full range of threaded insert systems, including free-running, Tangless, Keensert, and locking inserts, all installed in accordance with customer standards.

Packing

Portsmouth Aviation is proud to hold Military Packing Accreditation (MPAS), which we have maintained since 1994. This accreditation enables our highly trained technicians to pack products in full accordance with military and defence standards, ensuring the protection, safety, and longevity of components throughout storage and transportation. Our packing processes closely align with our stringent internal quality standards, providing customers with confidence that products are delivered in optimum condition and fully compliant with contractual and industry requirements.

Our state-of-the-art facilities and comprehensive expertise are channelled to our customers via our people and teams; working in close collaboration with our customers, we listen, challenge and innovate, adding value and reducing risk throughout the project.

Simon Escott, Managing Director

Our

Capabilities

Technical Services

Assembly (wip)

CNC Machining

Metal Fabrication

Metal Finishing

Paint & Finishing

Qualification, Inspection & Testing

Technical Services

Focused on design. At Portsmouth Aviation, Technical Services are an integral part of our business model. Our approach is bespoke and can be a game changer for your project. Designed to support and complement our traditional manufacturing capabilities, we have a wide range of core technical service competencies to ensure that we remain at the forefront of precision engineering industries.

Assembly (wip)

Assembly

CNC Machining

CNC Machining is a crucial part of Portsmouth Aviation’s in-house capabilities. Our state-of-the-art equipment and wide-ranging expertise set us apart in the industry. This has included ensuring our CNC machining equipment is of outstanding quality, maintaining our ability to provide efficacy and quality to our valued customers. Our experienced team bestows upon us a comprehensive knowledge of CNC machinery, ensuring that our customers receive the best possible final product.

Metal Fabrication

Metal fabrication and manipulation is an area of expertise that is essential to many of the projects we undertake. At Portsmouth Aviation, our specialist engineers have a multitude of experience in metal fabrication and their proficiency in welding is evident in the quality of their work.

Metal Finishing

Metal finishing at Portsmouth Aviation has the power to enhance the performance, durability, and protection of the components we produce, enabling our process technicians to create reliable and long lasting protective coatings that can withstand challenging environments and operational demands.

Paint & Finishing

Paint and finishing services at Portsmouth Aviation play a crucial role in ensuring the quality and durability of our engineering products. With meticulous attention to detail and the use of advanced coating technologies, these services ensure the longevity and optimal performance of critical components, reinforcing the company’s commitment to delivering high‑quality and reliable solutions to its customers.

Qualification, Inspection & Testing

Qualification, inspection, and testing are critical processes aimed at ensuring the reliability, performance, and compliance of engineering products or systems. These processes involve assessing and validating the design, manufacturing, and functionality of various components, materials, or entire systems. These processes help identify potential issues, weaknesses, or deficiencies early in the development or manufacturing stages, allowing for necessary improvements, adjustments, or corrective actions. Ultimately, qualification and testing contribute to delivering safe, reliable, and high‑quality engineering solutions that meet industry standards and customer needs.

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