Innovative Tooling Solutions

Agile, lightweight and intelligent production tooling

  1. AFD Systems
  2. What we do
  3. Innovative Tooling Solutions

innovative tooling solutions

AFD Systems delivers innovative tooling solutions that enable the accurate and efficient manufacture of components, systems and assemblies across aerospace, defence, and other highly regulated industries.

Our decades of experience in airframe manufacturing and advanced materials allows us to design and deliver lightweight, robust and intelligent tooling that supports both production and modification programmes.

We partner with OEMs, primes and Tier 1 and 2 supply chains to engineer turnkey, end-to-end tooling solutions to ensure uncompromising quality.

Excellence in tooling solutions

We design, implement and manufacture precision tooling systems that underpin efficient production workflows and support complex manufacturing operations.

Our tooling solutions are used globally, from retrofitting sensors and special mission platforms to finishing composite parts for aircraft and rotorcraft assemblies.

By combining traditional manufacturing with polymer additive technologies and composite materials, AFD Systems delivers agile, digital and future-ready tooling solutions that meet the evolving needs of modern aerospace and defence production.

Capabilities include:

  • Tool design and manufacture
  • Assembly jigs and fixtures
  • Drill and rout templates
  • Polymer additive tooling components
  • CAD and structural design
  • Design for Manufacture (DfM)

Our team brings together design, manufacturing and certification expertise to create fit-for-purpose tooling that improves precision and operational performance.

Our process and methodology

At AFD Systems, we combined highly skilled engineers with subject matter experts to deliver optimised tooling solutions tailored to our customers’ needs. Our approach integrates digital design, simulation and advanced manufacturing technologies to ensure each tooling system achieves the highest level of accuracy and performance.

Collaboration between our engineering and manufacturing teams allows us to exploit the full potential of additive manufacturing, advanced polymers and lightweight composites, delivering agile and high-integrity tooling for critical applications.

This integrated process ensures:
Lightweight, high-performance solutions

  • Reduced lead time and work
  • Seamless digital workflows from concept to manufacture
  • Full compliance with multiple industry standards and regulations

About AFD Systems

AFD Systems is a market-leading advanced engineering and manufacturing business, trusted by global aerospace and UK defence organisations.

With over 600 successfully completed engineering projects across 70 fixed-wing and rotary platforms, UAVs, drones and land systems, AFD delivers robust and technically-advanced solutions that drive the industry forward.

Headquartered in cutting-edge engineering facilities in North West England, AFD Systems is committed to engineering excellence, continuous improvement and a purpose to address complex challenges that contribute to a safer, more secure world.

Why choose AFD Systems?

AFD Systems acts as a seamless extension of client teams, combining advanced digital manufacturing technologies with deep engineering insight to accelerate project outcomes. Clients choose AFD Systems for:

  • Agile and efficient delivery
  • Reliable, trusted collaboration
  • High-quality, repeatable output
  • On-time, on-budget performance

our approach

Our approach is guided by a consistent set of values that ensures every project aligns with our clients’ mission goals:

  • CUSTOMER-CENTRIC | From beginning to end
  • INTEGRITY | In all that we do
  • INNOVATION | To remain in front
  • ONE TEAM | Making us stronger together

Standards and accreditations

AFD Systems is fully accredited and certified to deliver additive manufacturing solutions across a range of tightly controlled sectors. Our operations adhere to the following standards:

Related Case Studies

We engaged AFD on the Human External Cargo (HEC) programme at a critical point when EASA had just begun to scrutinise our first of many STC applications for the Load Carrying System / Basket Type 1. At this time AHUK faced several technical challenges and simply put, AFD offered quick and effective support; working as a team with us to resolve some challenging technical problems, enabling confidence to be built between AHUK and EASA at panel level, and ultimately leading to a successful STC application.

Gordon Bailey - Chief Designer, AIRBUS Helicopters UK

“AFD was engaged from start to finish in our Taipan Gun Mount programme, providing reliable specialist support in the Structures topic. During both the prototype and serial production phases, AFD supported both NOVA in solving complex strength issues, preparing the ground for a successful certification campaign. AFD offer a Turn-Key Structures solution for EASA DOAs by providing a team of experienced Stress Engineers backed up by independent Compliance Verification Engineers (CVEs).”

Gareth Dyer - Managing Director, Nova Systems

“AFD gave excellent service in all areas. When they joined the team the means of compliance for the structural airworthiness requirements were being re‐negotiated internationally. AFD quickly rationalised the HEC requirements and proposed a clear strategy for the strength substantiation and compliance demonstration, convincing EASA specialists in the process.”

Leon Winnert - DO Project Manager, AeroDAC

Sectors

AFD Systems is known globally for its work supporting customers in the aerospace and defence sectors, while it also has in-depth expertise in highly technical and regulated sectors such as medical, motorsport, nuclear, rail and space.

In the primary sectors of aerospace and defence, we provide engineering solutions for new design, modifications, repairs and reverse engineering for major airlines, special mission platform operators, military fleets, and VIP customers.

Aerospace
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Defence
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Space
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Nuclear
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Medical
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Rail
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Motorsport
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Trusted by organisations across the world