Recently, the television show Innovations with Ed Begley, Jr. met with a number of Aereos partners to discuss the new MAZAK machine at EulessAero. Here are a few highlights from those interviews. And stay tuned to our blog for more information on when the Aereos episode will air!

When Innovations arrived to highlight the new Mazak suite at EulessAero in the Dallas area, they delved into some important topics including customers, clearances and the future of the aviation industry. A few of the questions and answers are below, illustrating Aereos’ commitment to their customer and the future, as well as the highlights, of this exciting machine.

Discuss Aereos’ state-of-the-art equipment, and how does EulessAero meet the part-processing demands of today’s aerospace manufacturers?

“EulessAero manufactures airframe, landing gear and engine parts for commercial and military aircraft. The Mazak HCN-5000/50 is a very robust machine tool capable of machining all types of aerospace alloys in casting, forging, bar or block form. Set up time from running one job to the next job takes eight seconds.” -Christopher Papke, Southwest Regional Manager for Mazak, Inc.

Why is it important to focus on improvements in technology science and manufacturing processes when building parts for commercial aircraft?

“Margins for error are non-existent for commercial airlines, therefore machining tolerances are more precise than almost any other industry. Many of the newer materials—composites and metal alloys, are more difficult to machine than traditional aluminum, leading to higher scrap rates. Most aerospace component orders are for small quantities making cost efficient production extremely difficult.” -CP

How is Aereos committed to keeping the world flying safely and cost effectively?

“During its more than fifty years of operation, EulessAero has transformed from a company that fills orders EulessAeroto one that understands trends, forecasts needs and realizes patterns and market demands to benefit its customers. EulessAero has exponentially expanded the breadth of its abilities, increased its knowledge and experience base, and multiplied its capabilities by adopting state-of-the-art machines, production processes and employing top notch employees.” -Chris Baumann, COO of EulessAero

Today’s aerospace customers value short lead-times. Minimizing setup times and improvements in production efficiency are invaluable.

What are the “tight tolerances” in which your parts must be manufactured?

Jon Polliard, Manufacturing Engineer, EulessAero

Jon Polliard, Manufacturing Engineer, EulessAero

“Our vision is to keep the world flying safely, reliable and cost effectively. Knowing that our customers and their passenger and crew safety depends on us meeting and exceeding the specifications for our parts, is an enormous but rewarding responsibility.

Tight tolerance, simply put, is a variance of plus or minus .002 inches, and a very tight tolerance is 0.001 inches. It is very important that parts and products are manufactured to tight tolerance to insure they will fit, will perform as they are meant to and will not fail.” -Jon Polliard, Manufacturing Engineer at EulessAero

Discuss part failure and explain why it is not an option in the hot section of the aircraft engine.

“Part failure of ‘critical’ hot section of the aircraft parts is not an option due to safety. Technically speaking, Flight Safety ‘Critical’ Aircraft Part refers to any part, assembly, or installation containing a critical characteristic whose failure, malfunction or absence could cause a catastrophic failure resulting in loss or serious damage to the aircraft or an uncommanded engine shutdown resulting in an unsafe condition.” – JP

What are the key machine capabilities necessary for today’s aerospace manufacturers?

“Today’s aerospace customers value short lead-times. Minimizing setup times and improvements in production efficiency are invaluable. Options for network access also allow remote monitoring of production—expanding production capacity even when the shop is not staffed.” – CP

What part do these capabilities play in enabling EulessAero and other aerospace manufacturers to achieve the most demanding tolerances?

“The Mazak HCN-5000 ensures that manufacturers can machine all types of aerospace materials, as spindle performance can be matched to specific materials. Part production also benefits from the machine’s highly rigid spindle, numerous tool magazine options, quick rapid traverse speed and vibration-free acceleration/deceleration to meet tight tolerances and smooth finishes.” – CP

What future trend or impact do you see EulessAero having on the industry?

“The aviation industry has never hesitated adopting new technology and neither will EulessAero. Technological advances in the way planes are built, parts are transported, and aircraft are maintained have been particularly rapid in the twenty first century. To remain competitive, EulessAero will continue to adopt technology and processes to keep up with these advances.” -William Montgomery, Partner at Aereos

Why are the people, and their know-how, equally important to the company?

“As EulessAero invests in new equipment and pioneers new production capabilities— including more difficult to machine materials and complex shapes, it is only through our people’s commitment to develop the skills, processes and capabilities that we will fully capitalize on all the new technology.” -WM

How does focusing on the people help the company provide the best parts to customers?

“We believe that to provide the best solutions for our customers, we need to regard our people the same way we regard our customers. We need to be authentic and treat our customers and each other with genuine respect. We need to be trustworthy and act with integrity to meet all our commitments with our customers and amongst ourselves.” -WM

From their website: Innovations is an award-winning television series hosted by actor, director and environmentalist, Ed Begley Jr., and is dedicated to bringing viewers the most up-to-date, cutting edge information across a vast array of industries. From health and wellness to global business, renewable energy, and more, Innovations features practical solutions and important issues facing consumers and professionals alike.


Jon Polliard passed away in the early part of 2019. His work at Aereos was very important, as was his friendship. Our tribute to Jon can be found here, and he will always be a part of EulessAero and Aereos.