The First Step To Getting Off The Ground

Is One We Will Make Together

Manufacturing

Born From Aerospace, Defense And Government Modernized Manufacturing, Our Expert Capabilities Combine State-Of-The-Art Knowledge, Equipment And Facilities To Deliver Superior Quality And Fail-Safe Performance For Your Most Critical Missions.

01

INNOVATIVE

Design Engineering

Sidus provides quality in-house Design Engineering services from up-front analysis to integration, assembly, and test. Our ISO 9001:2015 / AS9100D certified and Boeing DPD/MBD approved engineering capabilities include the ability to perform initial design concepts or value-add engineering change recommendations to existing engineering.

02

PRECISION

Machining

Sidus provides it all, the expert engineers, skilled technicians and state-of-the-art equipment to support precision machining, fabrication, and assembly for prototypes, test articles, one-offs, low-rate initial production up through high volume swiss screw machining production.

03

COST-EFFECTIVE

Waterjet Cutting

Sidus Space offers a cost-effective waterjet cutting solution whether you need a single part, a batch of prototypes, or a production order.

04

STATE-OF-THE-ART

3D Printing

From early-stage product development to functional finished parts, Sidus offers commercial and industrial-grade additive manufacturing solutions. Our 3D printers enable us to provide rapid manufacturing with industrial micron-level laser scanning accuracy and 50 µm repeatability.

05

EXPERT

Cable/Wire Harness Fabrication

Sidus has an 8,000 square-foot reconfigurable avionics lab that produces a wide range of space system flight and ground cables, medical wire harnesses, military harness assemblies, electronic chassis, electro-mechanical assemblies, and fiber optic assemblies.

Sidus has extensive experience assembling electronics, including soldering, crimping, multi-pinned connector terminations, fusion splicing, molding, potting, and testing.

Ready to Access Space?

Complete our quick 5 minute Mission Planner and we will help get you started. It’s OK if you leave things blank, we’re here to fill in the gaps.

Ready to Access Space?

Complete our quick 5 minute Mission Planner and we will help get you started. It’s OK if you leave things blank, we’re here to fill in the gaps.
Scroll to Top

01

MANUFACTURING

Design Engineering

Sidus’s multidisciplinary engineering experience and talent cover a broad spectrum of capabilities, enabling an even more comprehensive range of projects.

Capabilities:

  • Requirements Definition
  • Product development and process optimization
  • Verification/Validation (multiple checks and balance)
  • Meets specification and intended purpose
  • Model Based Systems Engineering
  • Use of visual modeling vs document-based information exchange
  • 3D CAD & 2D Engineering Release
  • Managing, planning, scheduling and controlling
  • Test Procedures and Performance
  • Meets customer driven requirements
  • Operations/Maintenance Manuals
  • Fully integrated and procedurally driven
  • System Integration
  • Horizontal sub-system integration approach to projects and programs
  • Design for Life Cycle Cost & Manufacturing
  • Incorporation of innovative design manufacturing
  • Model Based Data Control
  • Complex design verification/validation
  • Finite Element and Failure Mode & Effects Analysis
  • Design for Manufacturability

02

MANUFACTURING

Precision Machining

CAD/CAM Software:

  • Mastercam
  • GibbsCam
  • Siemens NX
  • Volumill
  • SolidWorks
  • FeatureCam

02

MANUFACTURING

Precision Machining

Certifications:

  • AS9100 Rev D
  • ISO 9001:2015
  • AWS welding
  • NASA Std 8739.4
  • J-STD-001-IPC

03

MANUFACTURING

Precision Waterjet Cutting

Waterjet cutting is a cold-cutting technique that leverages water (or a mix of water and abrasives, such as garnet) to cut through materials via rapid erosion. This process is suitable for cutting various materials—ranging from soft goods like foam and carpet to rigid materials like ceramic and metal—up to 5.5 inches thick. Unlike laser or plasma cutters, waterjet cutting tools do not rely on thermal mechanisms; instead, they eject water and an abrasive at three times the speed of sound. The pressurized water stream magnifies erosion to quickly and cleanly produce the necessary cuts on the material.

Waterjet Advantages:

  • Speed: Abrasive waterjet cutting is up to four times faster than conventional flat stock waterjet cutting.
  • Precision: Our machines meet the strictest tolerances, up to +/- 0.0010”.
  • Versatility: We cut a wide variety of materials with near net accuracy, virtually eliminating secondary finish machining.
  • High material usage: Waterjet cutting maximizes material usage through tight nesting, which lowers your cost per part. Taper is all but eliminated, with less than 1 degree in straight-line geometry.
  • No heat distortion: Waterjet cutting generates no heat, so the material edge is unaffected and reduces distortion to zero.
  • Finish cut: Waterjet cutting is considered a “finish cut,” immediately usable for signs and displays, which saves on finishing costs.
  • Cost-effectiveness: Cost savings per part are unmatched by any other cutting system.

Waterjet Design Considerations:

  • 3Round inside corners with a 0.030″ or larger radius
  • Avoid tightly toleranced features in thick materials
  • Avoid designing flimsy shapes

Industrial Applications:

  • Aerospace (aircraft engines, turbine blades, control panels, etc.)
  • Architectural (marble, tile, stone, ornamental components, etc.)
  • Biotech (pipes, tubes, disks, etc.)
  • Chemical (tanks, pipes, tubes, etc.)
  • Marine (pipes, pumps, etc.)
  • Mechanical (pumps, disks, rings, etc.)
  • Packaging (inserts, foam, etc.)
  • Pharmaceutical (tubing, disks, etc.)
  • Signage (lettering, artistic designs, etc.)
  • Vacuum (tubing, pumps, pipes, etc.)
  • Welding (pumps, disks, rings, etc.)

04

MANUFACTURING

3D Printing

Using Continuous Fiber Fabrication technology, we can produce parts in hours that are stronger than 6061 Aluminum and 40% lighter. Sidus provides internal engineering support to optimize the functional performance, product life-cycle, and accuracy of your specific 3D printed technology to ensure repeatability and consistency across prints.

Capabilities:

  • Functional Prototypes and Models
  • Production Parts
  • End-life Production
  • Tool Development
  • Patterns and Molds
  • Jigs and Fixtures
  • Fly-Away Parts

05

Expert

EXPERT Cable/Wire Harness Fabrication

Our Avionics Quality Manager is a NASA 8739.4 level B certified instructor with over ten years of aerospace quality experience allowing for expedited training and workforce certification. Our IPC-J-STD-001 accredited technicians adhere to NASA work standards KSC-E-165, KSC-GP-864, KSC-STD-132, all required for NASA 8739.4 credentials with other industry-standard certifications.

Avionics Lab Capabilities:

  • Cable Assemblies: HO (power), ML (data), FO (data)
  • Connectors: General purpose, rectangular, high density, miniature, power, commercial, coax (TNC, SMA, HN, and Tri-axial), fiber optic (ST, FC/PC, SC, LC)
  • Terminations: Stripping (thermal and mechanical), soldering (NASA STD – 8739.4, NHB 5300 and MIL-STD 454), crimping, butt and parallel splices up to 4/0 AWG, fusion splicing
  • Contacts & Terminals: From 26 AWG up to 4/0 AWG, flag terminals up to 4/0 AWG
  • Mechanical: -500 to +2,000 lbs for pull test requirements to certify/verify good crimps/splices (performed on test samples)
  • Testing: DC Hipot (manual to 3000 Volts Direct Current (VDC) and automatic to 1500VDC), Alternating Current (AC) dielectric (manual to 3000 VAC), continuity (manual and automatic). We use automated testing to minimize the time for end-to-end connection testing.
  • Chemical Mix Crib: Consists of OSHA-approved laboratory vent hoods, multiple ovens for elevated temperature chemical cures, and a de-aeration station for performing certified processes such as bonding, potting, etc. Sidus has an 8,000 square-foot reconfigurable avionics lab that produces a wide range of space system flight and ground cables, medical wire harnesses, military harness assemblies, electronic chassis, electro-mechanical assemblies, and fiber optic assemblies. Sidus has extensive experience assembling electronics, including soldering, crimping, multi-pinned connector terminations, fusion splicing, molding, potting, and testing.