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Kitting / Machining

Since your interconnect solution may require more than a single component, CarlisleIT delivers kitting solutions that assemble multiple parts and equipment needed for your systems under a single part number. Our goal is to optimize the process while speeding quality products that meet your unique needs. We also offer advanced machining capabilities that meet the growing need for precision machining in product development. That means you can access our unmatched capabilities through a single contact. 

Aircraft Modification Kits

  • Integrated Installation Kits

  • Service Bulletin Kits

  • Hardware Kits

Fiber Optic Test & Inspection Kits

  • CarlisleIT Fiber Optic Test Assemblies

  • Fiber Interface Cleaning Supplies

  • Test Instrumentation

Machining

  • Swiss Machining

  • Micro-machining

  • Electroplating Services

Aircraft Modification Kits

Whether your needs run from simple loose-parts kits to fully integrated solutions, CarlisleIT can build kits to your supplied drawings, to existing STCs or manufacturer service bulletins. We also offer kits for the many STCs we own. Researching complex system specifications, as well as sourcing, purchasing, and maintaining the many required components for the development of turnkey installation kits is at the heart of our commitment to servicing our customers.

Integrated Installation Kits
We design our installation kits to integrate the specific system being installed with the unique requirements of the customer's airframe type, and fabricate our kits to simplify the installation process. Each installation kit we build comes complete with appropriate components, per drawing specifications, and includes such items as cabling, wire harnessing, electronic and mechanical assemblies, annunciators, adapters, and associated mounting hardware and fittings. To maintain tight control of kit parts inventory, all installation kit components are individually labeled and poly-bagged or shrink-wrapped in easy-to-transport packages.

Before shipping, qualified on-staff Quality Control Inspectors check each kit to make certain that all parts have been manufactured in strict accordance with industry standards and meet stringent system requirements. With the help of our in-house FAA-certified DAR and DMIR personnel, kits are inspected as needed to ensure FAA compliance, and receive the appropriate conformity inspection tags and/or Parts Manufacturer Approval (PMA). Because we have over 25 years of experience supporting the aerospace industry with kitting solutions, you can be sure that our installation kits will streamline your installation process and that your avionics systems will work correctly the first time.

Listed below are some of the many systems that our Installation Kits support:

  • TCAS I & II 

  • MODE-S

  • GNLU

  • ADS-B

  • INS/IRS

  • Windshear

  • BRNAV 

  • SATCOM 

  • SATFONE 

  • CUR/FDR 

  • IFE 

  • Digital Displays

  • GSM 

  • EHIS 

  • GPS 

  • ACARS

  • MMR 

  • HUD

  • FMS 

  • GPWS 

  • EGPWS 

  • Air-to-Ground/TFTS 

  • Smoke/Fire Detection & Suppression

Service Bulletin Kits
CarlisleIT can assemble kits for manufacturer service bulletins to streamline the procurement and handling of the necessary parts. To help you avoid unnecessary stocking or pulling of individual parts, our kits arrive pre-packaged under a single part number with exactly what is needed to modify a single aircraft. No more unnecessary materials in the stock room or time consuming pulling of individual parts to perform modifications.

With our many years of experience working closely with avionics systems and airframe original equipment manufacturers (OEMs), CarlisleIT continues to meet the challenges of avionics installation provisioning by providing hardware kits that offer high-quality components, give reliable performance, and are installation friendly.

Hardware Kits
Our hardware kits are developed to support both retrofit and forward-fit avionics installation programs and conform to all ARINC and aerospace industry standards. To ensure on-time delivery, we maintain a comprehensive inventory of stocked parts as well as standard ARINC tray assemblies. Before final shipping, our qualified Quality Control Inspectors review kits to ensure they meet all drawing requirements and carry our manufacturer certificate of compliance.

Whether your program requires build-to-print or custom kit development, you can depend on our industry experience, product knowledge, engineering capabilities and flexible manufacturing to assist with your next commercial or military installation project.

Franklin, WI Facility
Phone: 800-327-9473
Fax: 414-421-5301

Fiber Optic Test & Inspection Kits

CarlisleIT offers complete testing kits with CarlisleIT Fiber Optic Test Assemblies, Fiber Interface Cleaning Supplies and Test Instrumentation. We consult with you to build testing kits tailored to their application, and can offer fully self-contained testing kits with Insertion Loss Test Kits, Visual Inspection Video Scopes, Optical Time-Domain Reflectometers (OTDRs), Optical Backscatter Reflectometers (OBRs) and other test devices.

Download our Fiber Optic Test, Inspection & Cleaning Kits Sales Sheet

CarlisleIT produces a full line of fiber optic test assemblies that can be used to connect fiber channels (DUTs) to test equipment interfaces. Often called Aerospace Measurement Quality Jumpers (AMQJs), Gold Cables or Reference Cables CarlisleIT test assemblies are custom designed and built to interface with any device to be tested and offer very low insertion loss, precision finished connector end-faces along with durable and flexible cabling. Our test harnesses simulate interfacing equipment connections to provide the most accurate testing results and are built for precision testing in the lab, on the tarmac and anywhere in-between.

CarlisleIT can provide test equipment appropriate to quantify fiber optic harness/installation performance and provide advanced diagnostic tools for fault detection and characterization in complex installations, or in scenarios where only one end of the channel is available for test interfacing.

  • Multimode and Singlemode insertion loss meters (benchtop or handheld units) with wavelengths of 660/850/1310/1550 nanometers

  • Optical Time-Domain Reflectometer (OTDR)

  • Backscatter Meters

  • Reflectance Meters

CarlisleIT also will help you select and provide instruments for visual inspection of connector end-faces and basic fault detection:

  • Visual LASER light sources

  • Video Scopes - Handheld or Benchtop

CarlisleIT offers a full line of Sticklers® fiber optic cleaning products for all common termini types. These easy-to-use products are perfect for technicians in the field or inside a factory. We can help you select the appropriate cleaning products tailored for your kit.

  • Non-aerosol cleaning fluids

  • Lint-free cleaning pads

  • Fiber interface cleaning swabs

  • Sized for all standard connector/contact sizes

Kent, WA Facility
Phone: 800-227-5953
Fax: 425-251-8826

Machining

We’re committed to providing you with the most advanced machining capabilities available to support your most ambitious projects. So CarlisleIT Pottstown is an ISO 9001:2008 registered facility providing high-accuracy Swiss Machining for the defense, electronics, aerospace, microwave and medical industries. We operate ultra-clean, modern CNC Swiss machinery. Swiss-style lathes are a unique lathe configuration that are able to provide parts complete, utilizing multiple spindles with extreme accuracy and at high speed. The Swiss-style lathe adds an extra element of support in close proximity to the cutting tool which minimizes cutting tool deflection and vibration, making them well suited for small or slender parts.

Leveraging the efforts of our skilled technicians and the diverse capabilities of our equipment through Cellular Manufacturing, CarlisleIT is well suited to handle short runs, prototypes and high-volume production. We routinely machine a variety of metals including aluminum, brass, copper and copper alloys, super alloys, exotic alloys, steels, stainless steels, and titanium & titanium alloys. In addition, we work with a large variety of plastics including Teflon, PPS, PEEK, Ultem 1000, Torlon, Vespel and Delrin, to name a few. Given the very unique nature of machining & measuring precision plastics we have dedicated an entire manufacturing cell for that purpose.

CarlisleIT boasts a full array of CNC Swiss machine tools with up to 11 axes for machining of the most complex devices in one operation. To satisfy the demands of the industries we serve our equipment is fitted with vibration-dampening automatic bar loading, high-pressure coolant systems, linear, circular & helical interpolation, high-speed milling & super-position machining. CarlisleIT employs lights-out manufacturing methods for complete efficiency and productivity.

Micro-machining and CNC Milling Services
Micro-machining is a key technology for many of the industries we serve. CarlisleIT provides micro-machining services utilizing our fleet of precision CNC Swiss machines. Our highly skilled technicians specialize in the art of producing the highest quality, micro-machined parts. Our facility houses advanced high-speed machine technology capable of turned diameters as small as .005" at high speed with the use of cutting tools in .004"-.006" range in not only metals but also plastics.

Our machinery and methods are directly tailored for the production of micro-sized components. For more information about our micro-machining manufacturing services or our other manufacturing capabilities, please contact us directly.

Electroplating Services
In support of our Swiss machining services, CarlisleIT offers high-quality electroplating services for the increased corrosion resistance and electrical conductivity of parts. Our developed barrel plating process imparts copper, low-stress nickel, and hard gold plating over a variety of substrates including copper-based alloys and stainless steels. Our state-of-the-art plating equipment features a computer-controlled process, with robotic load, unload, and transferring capabilities. Available pretreatment operations include an acid and alkaline-based cleaning, ultrasonic cleaning, etching and micro-etching, as well as chemical descaling. Plating is suitable for parts sized up to 1" in diameter and 1" in length.

All plating is held to the highest industry standards, in full compliance with ASTM B-488, MIL-G-45204, QQ-N-290, and ASTM B689. Plated parts are thoroughly tested with methods including adhesion, solderability, bake, DPA, XRF, steam aging, and nitric vapor testing. Inspections including optical and scanning electron microscopy are carried out for ensured accuracy and integrity. Lead times for plating are less than 2 weeks, with JIT delivery available. For more details about our barrel electroplating services, or the other capabilities we offer, please see the table below or contact us directly.

CarlisleIT
105 Jones Boulevard, Suite 102
Pottstown, PA 19464
(610) 495-4300

"They have a broad range of products; they’re willing to do the extra step to do something new."

- Bobbie A.