Featured Engineered to Order Aerospace Solutions

Automated Propeller
Blasting for Integrity

Our Customer required an automated blast cabinet to clean and prepare aircraft propellers as part of their structural integrity testing and inspection process. The goal was to remove coatings, corrosion, and contaminants without compromising the fine tolerances or surface conditions critical to propeller performance.
Clemco collaborated closely with our Customer’s engineering and QA teams to develop a solution that aligned with their FAA-regulated testing protocols and high manufacturing standards. Key design activities included:
- Assessment of propeller geometries and required surface finish outcomes
- Determination of abrasive media type and blast pressure suitable for aluminum and composite materials
- Ergonomic layout planning for safe operator access and efficient part loading/unloading
- Custom airflow and dust collection design to preserve visibility and cleanliness
- Space optimization to fit within their existing facility footprint
Clemco delivered a purpose-engineered blast cabinet tailored for precision propeller surface prep, featuring:
- A media recovery and reclaim system for consistent abrasive quality and reduced waste
- Adjustable part fixtures and staging to accommodate varying propeller lengths and configurations
- Fine-tuned blast nozzles and pressure controls to deliver uniform surface finishes without overblasting
- High-efficiency lighting and ventilation to ensure clear visibility and air quality
- Full operator integration and optional upgrade paths for future robotic automation customization
The delivered solution gave them the ability to efficiently prep and inspect propellers with confidence, improving throughput, enhancing safety, and maintaining strict quality assurance standards critical to aviation.

The U.S. Air Force needed a highly specialized blast solution to safely strip coatings and corrosion from the fuselage of A-10 Warthog aircraft, known for their rugged design and critical close-air support missions. The goal was to extend aircraft service life while maintaining surface integrity for repainting and structural inspections.
Clemco worked closely with Air Force engineers and maintenance teams to develop a custom-engineered solution using its I2R™ (Ideation to Realization) methodology. The design process involved:
- On-site discovery to assess space constraints and part handling logistics
- Selection of abrasive media and pressure profiles suitable for aircraft-grade aluminum
- Integration of operator safety features, including full PPE support and ventilation
- Consideration for future-proofing with automation compatibility
- Iterative modeling and mockup testing to validate coverage, ergonomics, and part movement
Clemco delivered a full-scale blast room capable of accommodating the entire A-10 fuselage, complete with:
- Heavy-duty part handling systems to support and rotate the aircraft structure
- High-capacity reclaim and dust collection systems for media efficiency and visibility
- Operator-controlled or semi-automated nozzle systems for precision blasting
- Environmental and safety controls in compliance with military-grade standards
- Training and support services to ensure smooth startup and long-term effectiveness
The result was a mission-ready, purpose-built blasting facility that reduced turnaround time, enhanced surface preparation quality, and supported the longevity of an iconic U.S. Air Force aircraft.

Aircraft Fuselage Blasting

Landing Wheel Maintenance

A major commercial airline needed a high-precision, automated blasting solution to remove coatings, corrosion, and debris from landing gear wheels as part of its FAA-required operational maintenance program. The process had to prepare the wheels for non-destructive testing (NDT) and visual inspection to verify structural integrity. Key goals included:
- Consistent surface preparation without overblasting
- Repeatability across hundreds of wheel types and sizes
- Reduced manual labor, operator fatigue, and human error
- Full compliance with FAA regulations and maintenance standards
The Clemco engineering team applied its engineered-to-order and automation expertise to co-develop the solution with the airline’s MRO (Maintenance, Repair, and Overhaul) team. The design process focused on:
- Evaluating wheel geometries, alloys, and blast finish specifications
- Integrating FANUC robotics for automated nozzle control and part manipulation
- Designing a cabinet with precise fixturing and programmable cycles
- Selecting abrasive media and pressure ranges that achieved optimal cleaning while preserving material integrity
- Including safety interlocks, real-time diagnostics, and user-friendly controls for ease of operation and maintenance
Clemco delivered a fully integrated, robotic automated blast cabinet purpose-built for airline wheel maintenance, featuring:
- A multi-axis robotic nozzle system for 360° coverage with consistent dwell and pattern control
- PLC/HMI touchscreen interface for quick recipe programming and cycle repeatability
- Media recovery and dust collection systems to maintain clean, efficient operation
- FAA-compliant process outputs, with documented performance validation
- Operator training and long-term support to ensure uptime and reliability
The solution allowed the airline to increase throughput, reduce rework, and ensure inspection-ready surfaces—all while lowering labor costs and supporting a safer, more standardized MRO process.