Custom aerospace friction materials and brake components from engineering brief to serial supply
FTL supports aerospace engineering, R&D and technical teams when a new programme needs a friction solution, an existing component is not performing as required, or a legacy part can no longer be sourced.
Friction-material formulation, component engineering, precision machining, bonding, finishing, testing, inspection and repeat supply can be managed through one accountable manufacturing route in North Wales.
When aerospace teams engage FTL
Start with the programme situation that has created the requirement.
A new aerospace programme needs a friction solution
The application and required function are understood, but the friction material, component construction or repeatable manufacturing route still needs to be established. FTL can support the route from early technical review through prototype development, testing, validation support and serial manufacture.
New Programme Support →A legacy component is threatening programme continuity
The original material, drawing, supplier or finished component is obsolete or no longer available, while the aircraft or system must remain operational. FTL can review the existing application and available evidence before proposing a redevelopment and revalidation route.
Legacy & Obsolete Reverse Engineering →An existing component is not performing as required
The engineering team is seeing inconsistent braking, excessive or unpredictable wear, thermal-performance concerns or variation between manufactured components. FTL can review the material, component, operating environment and available manufacturing evidence before proposing the next engineering step.
Performance Optimisation →The current supply chain has too many handovers
Material formulation, machining, bonding, finishing, inspection and delivery are divided between separate suppliers, making technical responsibility and issue resolution difficult. FTL can connect the relevant stages through one accountable manufacturing chain.
Single-Source Friction Manufacturing →The programme requires stronger quality and traceability controls
The project needs a defined manufacturing route supported by inspection, production records, batch or lot traceability and clearly allocated approval responsibilities.
Quality & Certifications →Aerospace friction applications beyond the wheel brake
Friction components are used throughout aircraft systems to brake, hold, lock, damp or limit motion. FTL's stated application experience includes the following component and system contexts.
Landing gear and ground braking
- Landing-gear locking pads
- Friction components used within landing-gear systems
- Trainer-aircraft wheel-brake linings
Actuation and holding systems
- No-back brakes
- Flap and slat actuation systems
- Electromagnetic actuation holding brakes
- Horizontal stabiliser trim-actuator brakes
- Aircraft door and ramp actuation brakes
Cargo-handling systems
- Cargo-handling system locks
- Cargo winch brakes
- Cargo hoist brakes
Cabin, restraint and motion-control applications
- Seat-track locking components
- Restraint locking components
- Rotary dampers
- Torque limiters
This is an application guide, not a catalogue of stock or universally approved parts. Each enquiry requires review of the specific component, function, operating environment, documentation requirements and validation route.
Define the application before selecting the friction material
An aerospace sector label or material name does not define a complete friction solution. FTL begins by understanding the function, operating environment, available component information and evidence the programme will require.
01Required function
Establish what the component must do:
- Brake
- Hold
- Lock
- Damp
- Limit torque
- Control movement within an actuation system
02Programme starting point
Confirm whether the requirement relates to:
- A new design
- An existing component
- An obsolete or unavailable component
- A performance concern
- A prototype programme
- A component moving into repeat production
03Operating environment
Relevant information can include:
- Temperature
- Load
- Speed
- Contamination
- Available installation space
- Operating conditions under which the component is applied
- Known braking, wear or thermal concerns
04Available component information
Useful evidence can include:
- Drawings
- Partial drawings
- Specifications
- Existing components
- Performance requirements
- Inspection information
- Test results
- Production or batch records
05Required material and component behaviour
The technical discussion can establish:
- Required friction behaviour
- Coefficient requirements
- Wear expectations
- Thermal-performance requirements
- Dimensional requirements
- Bonding or assembly requirements
- Production repeatability requirements
06Documentation and approval context
The programme should identify:
- Required inspection evidence
- Traceability requirements
- Customer documentation requirements
- Applicable certification or modification considerations
- FTL's responsibilities
- Customer or appointed-authority responsibilities
07Production and supply context
Later discussions can cover:
- Prototype quantities
- Expected annual volumes
- Production schedules
- Inventory holding
- Scheduled call-off
- Packaging
- Labelling
- Export and delivery requirements
Expected annual volumes are discussed after the initial application and technical fit have been established.
Three engineering routes for an aerospace programme
The appropriate route depends on what has prompted the enquiry.
New Programme Support
For a new aerospace application that needs a defined friction-material, component and manufacturing route. Support can include:
- Application review
- Material selection or formulation
- Engineering and component development
- Prototype manufacture
- Testing and inspection
- Validation support
- Transfer into repeat production
Legacy & Obsolete Component Reverse Engineering
For an aircraft or system that must remain operational after its original material, drawing, supplier or component becomes unavailable. Support can include:
- Existing-component review
- Dimensional and application assessment
- Component redevelopment
- Replacement friction-material route
- Prototype manufacture
- Testing and revalidation support
- Controlled repeat supply
Friction System Performance Optimisation
For an existing friction component or system with inconsistent braking, wear, thermal or repeatability concerns. Support can include:
- Symptom and evidence review
- Operating-condition assessment
- Material and component investigation
- Prototype or comparative-component manufacture
- Testing and inspection
- Support for the agreed implementation route
What FTL can deliver within an aerospace programme
Not every project requires every stage. FTL can support the relevant element or connect the complete route from friction-material work through finished-component supply, with material selection following the application review rather than a material-family name alone.
A stage-gated path from aerospace requirement to repeat supply
The detailed route varies by programme, but each stage should produce enough evidence to support the next engineering decision.
Establish technical fit
- The application
- The required function
- New, existing or obsolete
- Current programme stage
- Immediate technical or continuity concern
- Information currently available
Define operating and programme requirements
- Temperature, load, speed, contamination
- Required friction behaviour
- Component and installation constraints
- Documentation requirements
- Applicable validation considerations
Establish material and component route
- Whether an established material may suit
- Whether formulation work is required
- Whether component development is required
- Which machining, bonding, finishing, inspection stages apply
- What remains unknown
Agree prototype, test and responsibility plan
- What FTL will manufacture
- Which variants will be evaluated
- Which dimensions or characteristics inspected
- Which tests FTL will complete
- What evidence the customer requires
- FTL vs customer/authority responsibilities
Manufacture the prototype components
- Material-manufacturing stages
- Machining
- Bonding
- Surface preparation
- Finishing
- Assembly
- Inspection
Test, inspect and review
- Complete agreed testing and inspection
- Review evidence against requirements
- Refine material, geometry or route where needed
Support the agreed approval route
- Provide engineering, manufacturing, test, inspection and traceability evidence in scope
- Final component, system, aircraft, modification or regulatory approval responsibilities agreed per programme
Transfer into controlled repeat supply
- Repeat-production controls
- Inspection and traceability requirements
- Inventory holding
- Scheduled call-off
- Customer-specific packaging and identification
- Export documentation, international delivery
Quality, traceability and approval responsibilities made explicit
FTL's aerospace quality-management systems and registrations provide relevant organisational and supply-chain assurance, but they are not automatic product approval for every application. Inspection, testing and batch or lot traceability are agreed per programme; the certified scope and its applicability to an individual project are confirmed on the Quality & Certifications page.
A genuine aerospace qualifier the programme must settle early is who holds final approval. FTL can support the agreed validation or modification route with evidence from its engineering, manufacturing, testing and inspection work, and the scope must state what FTL will demonstrate, what testing FTL will complete, which evidence FTL will supply, whether customer or system-level testing is also required, and who holds final design, aircraft, modification or regulatory approval responsibility.
The evidence aerospace buyers need before approving a route
Can the proposed material match or improve the required performance?
FTL can review the existing material, application and required behaviour before proposing an established, optimised or newly developed material route. Whether current performance can be matched or improved depends on:
- The operating environment
- Available component evidence
- Defined acceptance criteria
- Agreed test conditions
- The wider component and system context
No outcome should be guaranteed before that work is completed.
Is the solution already proven in service?
How does FTL support consistent quality and repeatability?
Can FTL support the programme beyond material supply?
One accountable chain from friction formulation to finished aerospace component
A traditional route can divide the programme between a friction-material producer, machinist, bonder, finisher, test provider, inspector and logistics supplier. FTL can connect the relevant stages through one engineering and manufacturing route, helping reduce avoidable handovers and keep the material, component and production decisions aligned.
The connected FTL route
- Application and requirements review
- Friction-material selection or formulation
- Component engineering
- Friction and metallic-component machining
- Bonding and surface preparation
- Finishing and assembly
- Testing and inspection
- Production documentation and traceability
- Inventory, call-off and worldwide supply
What this can mean for the programme team
- One technical and commercial route
- Fewer supplier handovers
- Clearer accountability when technical questions arise
- Connected material and component decisions
- Continuity between prototype and repeat manufacture
- Inspection and traceability linked to the production route
- Fewer separate purchase orders and logistics touchpoints
- A clearer route into scheduled supply
Actual lead-time, procurement or cost improvements depend on the existing supply route and agreed programme scope.
A manufacturing route built around aerospace programme continuity.
The intended outcome is not simply delivery of a friction material. It is a defined route through the engineering, production, inspection and supply decisions needed for the programme. Potential programme outcomes include:
- A friction-material route defined around the application
- A complete component designed or redeveloped for manufacture
- Fewer separate suppliers and technical handovers
- Clear responsibility across connected production stages
- Agreed test, inspection and documentation requirements
- Batch, lot and production traceability
- Continuity from prototype development into repeat production
- An alternative source for a legacy or obsolete component
- Scheduled call-off and inventory arrangements where agreed
- Customer-specific packaging, identification and worldwide delivery
Performance, approval, programme timing and supply outcomes depend on the application, evidence available, agreed technical scope and customer responsibilities.
Case example: keeping an aircraft operational after component obsolescence
SDTS approached FTL after the original aircraft brake pad was no longer available. FTL worked with SDTS to redesign the pad, establish a suitable material route and manufacture a component aligned with the stated aeronautical technical requirements. The work supported SDTS in certifying a modification applicable to its aircraft.
“To continue flying our aircraft, we approached FTL to find replacement solutions for our brake pad problem, as the original part was no longer available on the market. The quality of our discussions, from both a technical and commercial standpoint, FTL's responsiveness in redesigning the pad with a material that meets aeronautical technical requirements, and their ability to adapt to our aeronautical environment allowed us to certify a modification applicable to our aircraft. The quality of the manufactured product is remarkable. Thanks to FTL, we can continue to fly, land, and brake safely.”
Olivier Moulin SDTS
Proof points supported by the case
- Original component no longer available
- Requirement to maintain aircraft operation
- Technical and commercial collaboration
- Component redesign
- Replacement friction-material route
- Aeronautical technical requirements
- Support for a customer modification-certification route
- Manufactured replacement component
Customer proof
Is FTL the right aerospace manufacturing route?
FTL is a strong fit when:
- Your team has an engineering brief rather than a stock-parts request
- A new aerospace programme needs a friction solution
- An original material, drawing or component has become obsolete
- An existing component has braking, wear or thermal-performance concerns
- The requirement involves a custom friction material or complete component
- Prototype work may need to progress into repeat manufacture
- Inspection, traceability and documentation matter
- You want to reduce the number of suppliers across the connected route
- The finished components need scheduled or worldwide supply
A different route may be more appropriate when:
- You need an off-the-shelf aircraft part immediately
- You are purchasing only by an established part number
- You need a stock catalogue rather than engineering support
- You are seeking a consumer or general replacement-pad product
- Price is the only selection criterion and no technical review is required
Frequently asked questions about aerospace friction materials and components
What aerospace friction materials does FTL work with?
Does FTL manufacture complete aerospace components or only friction material?
Which aerospace applications can FTL support?
Can FTL support a programme before the design is complete?
Can FTL reverse engineer an obsolete aircraft brake component?
Can FTL match or improve an existing material's performance?
Is every FTL aerospace solution already proven in service?
Is FTL AS9100 or EN9100 certified?
What testing and inspection can FTL support?
Does FTL provide final aircraft or regulatory approval?
How quickly can FTL supply an aerospace component?
When are price and annual volumes discussed?
Does FTL sell standard aerospace parts by part number?
Can FTL supply aerospace customers outside the UK?
Bring FTL the aerospace application, component or continuity problem.
Tell FTL what the component needs to do, what information your team currently has and what has prompted the enquiry. A short initial brief is enough to begin. The relevant technical, engineering and commercial team members can then review the operating environment, material route, component requirements and most appropriate next step.
Optional drawing or specification upload available. No long technical questionnaire, standard price or guaranteed programme timescale is required before the first conversation.