{"id":58653,"date":"2026-08-10T11:36:42","date_gmt":"2026-08-10T09:36:42","guid":{"rendered":"https:\/\/www.expo21xx.com\/news\/?p=58653"},"modified":"2026-08-10T11:52:29","modified_gmt":"2026-08-10T09:52:29","slug":"transforming-aerospace-challenges-into-success","status":"publish","type":"post","link":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/","title":{"rendered":"Transforming Aerospace Challenges into Success"},"content":{"rendered":"\n

For over 40 years, the German grinding<\/a> machine manufacturer KAPP NILES<\/a> and the American vertical-lift aircraft specialist Bell have been working together. Their collaboration has helped shape the aerospace industry.<\/p>\n\n\n\n

\"\"
Photo by KAPP NILES<\/figcaption><\/figure>\n\n\n\n

The helicopters and tiltrotors produced by Bell Textron Inc., a Textron Inc. (NYSE: TXT) company, a leading specialist in vertical-lift aircraft in the United States, are in operation worldwide. For over 40 years, the company has relied on machines from KAPP NILES for the final machining of its gears. \u201cBell is an innovative, very quality-conscientious company. We make the finest gears in the world\u201d, emphasises Kyle Kendall, Principal Equipment Engineer at Bell. \u201cAnd we depend on KAPP NILES machines to do that.\u201d <\/p>\n\n\n\n

Since 1935, Bell has been a pioneer in aviation. Its rotorcrafts are used not only in civilian applications but also for transportation, medical, rescue and military services. In special mission and emergency operations, these helicopters are used to deliver supplies to hard-to-reach areas and, above all, to carry out rescues in challenging situations. \u201cWe want people to know that Bell is laser focused on quality to ensure we get our customers back on the ground safely and home to their families\u201d says Kendall. <\/p>\n\n\n\n

Built to Last a Generation<\/h3>\n\n\n\n

The relationship between KAPP NILES and Bell began in the late 1980s with a VAS-type machine \u2013 a predecessor of today\u2019s VX series. Profile grinding machines of this series are ideally suited for aerospace applications, where exceptional precision is required. In the 1990s and 2000s, Bell equipped its production facilities with almost a dozen additional machines, many of which remained in service until recently.<\/p>\n\n\n

\n
\"\"
Machinist Scott Phillips, Principal Equipment Engineer Kyle Kendall (both from Bell), and Area Sales Manager Arnt Lachetta during the pre-delivery inspection of a VX 59 from KAPP NILES at the company headquarter in Germany.
Photo by KAPP NILES<\/figcaption><\/figure><\/div>\n\n\n

\u201cWhen your machines last over 30 years, that\u2019s a pretty good stamp of approval for a quality machine\u201d, emphasises Kendall. In recent years, Bell has gradually replaced the older machines with new VX 59 models. For Kendall and his team, it was a clear decision: \u201cOver the lifetime of the older machines, they\u2019ve proven themselves. They lasted beyond what they were expected to.\u201d <\/p>\n\n\n\n

One of the machinists at Bell is Scott Phillips. \u201cI think the VX machines are very versatile. All our helicopter models from the past four decades have been fitted with gears ground on KAPP NILES machines. In recent years, most of these parts have been produced on VX 59s within the tolerances we expect.\u201d <\/p>\n\n\n\n

The latest generation of machines are equipped with an optional zero-point clamping system. This allows set-up times for grinding spindles and additional grinding heads to be reduced by around 85\u202f% compared with the original duration. \u201cIt speeds up the set-up time significantly. We\u2019ve also noticed that there are no differences between operators anymore. It\u2019s more plug-and-play.\u201d <\/p>\n\n\n\n

Lead the Aerospace Industry<\/h3>\n\n\n
\n
\"\"
\u201cThanks to the AMS function developed for us, we can measure workpieces directly on the machine \u2013 saving months of time over the past 30 years,\u201d says machinist Scott Phillips.
Photo by KAPP NILES<\/figcaption><\/figure><\/div>\n\n\n

For Bell\u2019s team, it\u2019s not only the reliability of the machines that counts. \u201cIt\u2019s also the service and the availability of spare parts\u201d, points out Phillips. \u201cWe don\u2019t just achieve fantastic results with KAPP NILES \u2013 we also have a close relationship with their service team.\u201d <\/p>\n\n\n\n

One of the most significant projects was the introduction of an integrated measurement system (AMS) in the 1990s. \u201cThis project established the way we work today and has since gained broad adoption, helping to lead the aerospace industry\u201d, Phillips explains. Arnt Lachetta, Area Sales Manager at KAPP NILES, recalls: \u201cBell reached out and asked for a special function on the machine to measure and document workpiece characteristics. In a close collaboration, we developed the AMS function.\u201d<\/p>\n\n\n\n

With an onboard Renishaw measuring system, AMS is used to measure multiple points along the profile and lead direction of the gear. This inspection process is performed before and after grinding. The procedure ensures that the gear surface is properly finished at every point and that excessive material is not removed from the hardened layer.<\/p>\n\n\n\n

\u201cAMS was an important development. Pretty much every gear that we grind nowadays is AMSed\u201d, adds Phillips. \u201cIt brings reliability and significant time savings. Not just in cycle time, but by eliminating the need to move parts between machines for measurement. As we\u2019ve been using AMS for more than 30 years, the time we saved isn\u2019t measured in hours or days, but in months.\u201d Due to the significant benefits of this function on VX machines, KAPP NILES has recently revised and improved it based on Bell\u2019s requirements.<\/p>\n\n\n\n

Increased Productivity with Generating Grinding<\/h2>\n\n\n\n

In addition to the VX machines, Bell has been using a KX 500\u202fFLEX for the past five years. This machine marked the company\u2019s first experience with generating grinding. Lachetta recalls: \u201cBell was looking for a way to grind planetary gears with relatively large batch sizes more productively, without compromising quality. Many of our customers use generating grinding for both roughing and finishing. However, Bell\u2019s production regulations do not allow this.\u201d<\/p>\n\n\n\n

The approved production process requires the gear to be CBN-ground during the finishing cycle. \u201cSo, we came up with the idea of combining both tools\u201d, explains Lachetta. \u201cWith our KX 500 FLEX, we found the ideal combination: rough machining is done using generating grinding, resulting in significant time savings, while finishing with CBN profile grinding wheels delivers the usual high-quality finish.\u201d<\/p>\n\n\n\n

\u201cChanging from profile grinding to a combination with generating grinding has been a game changer\u201d, says Phillips. \u201cWe\u2019ve reduced runtime by about 70 per cent, which is huge today. At the same time, the KX 500 FLEX is very consistent. We\u2019re saving a lot of time without losing the quality that we\u2019re used to seeing on a KAPP NILES machine. We\u2019ve had such a good experience that we\u2019re considering a second KX machine.\u201d<\/p>\n\n\n\n

The Right Machine for Every Gear<\/h3>\n\n\n\n

Two machines, now known as the KNG master series, complete the fleet of KAPP NILES grinders at Bell. These are used to produce very large components with high workpiece weights. \u201cBy combining these three machine types for the final gear machining, we achieve outstanding results. Having the right machine type for every workpiece is key to success\u201d, emphasises Phillips.<\/p>\n\n\n\n

Another factor contributing to the successful collaboration is the subsidiary KAPP TECHNOLOGIES L.P. in Boulder, USA. Due to U.S. ITAR regulations, non-U.S. citizens are not permitted to access certain technical data. \u201cMany tools can now be manufactured directly in the USA, significantly reducing delivery times\u201d, says Lachetta.<\/p>\n\n\n\n

Overcoming Challenges<\/h3>\n\n\n\n

Bell and KAPP NILES share many years of experience and a strong drive to move forward together. \u201cSometimes Bell comes with requirements that are challenging for us\u201d, notes Lachetta. \u201cThese tasks push us to our limits \u2013 and beyond. This is incredibly valuable to us, as we not only support our partner, but also grow through these challenges ourselves. The fact that we are now a market leader in the aerospace sector is partly due to Bell\u2019s requirements helping us improve.\u201d<\/p>\n\n\n\n

\u201cWe set high standards for ourselves and our products. That\u2019s why we sometimes require special solutions\u201d, says Kendall. \u201cBell does unique things, and we need a partner who truly cares. With KAPP NILES, we feel supported by a team that values our goals and growth as much as we do. We know we can rely on them, that\u2019s why we keep coming back.\u201d<\/p>\n\n\n\n

For more information: kapp-niles.com<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

For over 40 years, the German grinding machine manufacturer KAPP NILES and the American vertical-lift aircraft specialist Bell have been working together. Their collaboration has helped shape the aerospace industry. The helicopters […]<\/p>\n","protected":false},"author":3,"featured_media":58690,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[641],"tags":[3272,3273,805,617,2098],"class_list":["post-58653","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-metalworking","tag-cnc-machine-centres","tag-gear-thread-rolling-machines","tag-grinding","tag-metalworking-industry","tag-superfinishing"],"yoast_head":"\nTransforming Aerospace Challenges into Success - EXPO21XX.com NEWS<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Fabian Becker\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"7 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/\",\"url\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/\",\"name\":\"Transforming Aerospace Challenges into Success - EXPO21XX.com NEWS\",\"isPartOf\":{\"@id\":\"https:\/\/www.expo21xx.com\/news\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage\"},\"image\":{\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg\",\"datePublished\":\"2026-08-10T09:36:42+00:00\",\"dateModified\":\"2026-08-10T09:52:29+00:00\",\"author\":{\"@id\":\"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/ca78ee84b18a19f8fe3509e73fa1f256\"},\"breadcrumb\":{\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#breadcrumb\"},\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage\",\"url\":\"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg\",\"contentUrl\":\"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg\",\"width\":260,\"height\":159},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\/\/www.expo21xx.com\/news\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"Transforming Aerospace Challenges into Success\"}]},{\"@type\":\"WebSite\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/#website\",\"url\":\"https:\/\/www.expo21xx.com\/news\/\",\"name\":\"EXPO21XX.com NEWS\",\"description\":\"Robotics and industrial factory automation, sensors, material handling and renewable energy news magazine\",\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\/\/www.expo21xx.com\/news\/?s={search_term_string}\"},\"query-input\":{\"@type\":\"PropertyValueSpecification\",\"valueRequired\":true,\"valueName\":\"search_term_string\"}}],\"inLanguage\":\"en-US\"},{\"@type\":\"Person\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/ca78ee84b18a19f8fe3509e73fa1f256\",\"name\":\"Fabian Becker\",\"image\":{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/image\/\",\"url\":\"https:\/\/secure.gravatar.com\/avatar\/bc48f9ac5f1d3f01e6a3215f0c87d280?s=96&d=mm&r=g\",\"contentUrl\":\"https:\/\/secure.gravatar.com\/avatar\/bc48f9ac5f1d3f01e6a3215f0c87d280?s=96&d=mm&r=g\",\"caption\":\"Fabian Becker\"},\"url\":\"https:\/\/www.expo21xx.com\/news\/author\/fabian\/\"}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Transforming Aerospace Challenges into Success - EXPO21XX.com NEWS","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/","twitter_misc":{"Written by":"Fabian Becker","Est. reading time":"7 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"WebPage","@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/","url":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/","name":"Transforming Aerospace Challenges into Success - EXPO21XX.com NEWS","isPartOf":{"@id":"https:\/\/www.expo21xx.com\/news\/#website"},"primaryImageOfPage":{"@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage"},"image":{"@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage"},"thumbnailUrl":"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg","datePublished":"2026-08-10T09:36:42+00:00","dateModified":"2026-08-10T09:52:29+00:00","author":{"@id":"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/ca78ee84b18a19f8fe3509e73fa1f256"},"breadcrumb":{"@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#breadcrumb"},"inLanguage":"en-US","potentialAction":[{"@type":"ReadAction","target":["https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/"]}]},{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#primaryimage","url":"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg","contentUrl":"https:\/\/www.expo21xx.com\/news\/wp-content\/uploads\/kappes.jpg","width":260,"height":159},{"@type":"BreadcrumbList","@id":"https:\/\/www.expo21xx.com\/news\/transforming-aerospace-challenges-into-success\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/www.expo21xx.com\/news\/"},{"@type":"ListItem","position":2,"name":"Transforming Aerospace Challenges into Success"}]},{"@type":"WebSite","@id":"https:\/\/www.expo21xx.com\/news\/#website","url":"https:\/\/www.expo21xx.com\/news\/","name":"EXPO21XX.com NEWS","description":"Robotics and industrial factory automation, sensors, material handling and renewable energy news magazine","potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/www.expo21xx.com\/news\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-US"},{"@type":"Person","@id":"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/ca78ee84b18a19f8fe3509e73fa1f256","name":"Fabian Becker","image":{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/www.expo21xx.com\/news\/#\/schema\/person\/image\/","url":"https:\/\/secure.gravatar.com\/avatar\/bc48f9ac5f1d3f01e6a3215f0c87d280?s=96&d=mm&r=g","contentUrl":"https:\/\/secure.gravatar.com\/avatar\/bc48f9ac5f1d3f01e6a3215f0c87d280?s=96&d=mm&r=g","caption":"Fabian Becker"},"url":"https:\/\/www.expo21xx.com\/news\/author\/fabian\/"}]}},"_links":{"self":[{"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/posts\/58653","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/comments?post=58653"}],"version-history":[{"count":1,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/posts\/58653\/revisions"}],"predecessor-version":[{"id":58657,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/posts\/58653\/revisions\/58657"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/media\/58690"}],"wp:attachment":[{"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/media?parent=58653"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/categories?post=58653"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.expo21xx.com\/news\/wp-json\/wp\/v2\/tags?post=58653"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}