Advanced structures and components

Marshall is a globally respected provider of advanced structures and complex subsystems that meet the toughest engineering challenges across civil and military aviation applications.

Whether working from pre-defined user requirements or from a blank slate as a UK CAA Part 21J Design Organisation, few companies can match Marshall’s depth of expertise and breadth of capabilities. Our NADCAP-accredited engineering team includes structural, electrical, interior, integration, systems, stress, weight, aerodynamics and avionics designers.

Our state-of-the-art Advanced Manufacturing Solutions site in Cambridge has been awarded top supplier status by Boeing for our ability to deliver on time and to the highest quality and safety standards.

No matter how bespoke, complex or challenging their requirements, we take projects all the way from specification and design through to manufacturing, testing, qualification, integration and support. We are able to flexibly scale to meet project needs – whether producing a one-off prototype or thousands of units over a yearslong production run.

Thanks to our investment in facilities and emphasis on continuous improvement to our processes, we are able to adopt and apply the latest production techniques across the full spectrum of materials.

Explore our end-to-end capabilities

Design
- Systems design
- Design engineering
- Tooling design
- CATIA programming
Manufacturing
- 3D printing/additive manufacturing
- Sheet metal fabrication
- Milling and turning (CNC and manual)
- Welding
- Prepreg
- Resin infusion
- Filament winding
- Laser wire printing
- Curing
- Trimming
- Tool and cutter grinding
- Chemical processing
- Thermal processing/heat treatment
- Painting
- Engraving
- Pipework
- Composite assembly
- Mechanical assembly
- Electrical assembly
Testing
- Model-based systems engineering (MBSE)
- Ground/static testing (rig testing)
- CMM and manual inspection
- Flight testing
- Structural analysis, including fatigue and damage tolerance
- Flammability exposure testing
- Factory acceptance testing
Qualification
- Performance and design certification
- Testing verification
- Supply chain qualification
Integration
- Aerodynamic integration
- Avionic and control logic integration
- Electrical integration
- Line Replaceable Units (LRUs)
Support
- Continued airworthiness management
- Spares
- Non-standard repairs
- Technical documentation

Fuel tanks

For over four decades, Marshall has produced auxiliary fuel tanks that have been retrofitted to 10 commercial and military aircraft types across five major OEMs including Airbus, Bombardier and Boeing. We offer a safe, reliable and certified solution needed to meet range-extension requirements, today and in the future.

We have been working extensively with Boeing since 1997, initially providing auxiliary fuel tanks for commercial airliner variants such as the 747-400ER and 777-220LR Worldliner. Since 2009, we have been Boeing’s exclusive supplier of auxiliary fuel tanks for the globally successful P-8 Poseidon maritime patrol aircraft, end customers for which include the United Kingdom, United states, Australia, India, New Zealand and Norway.

The auxiliary fuel tanks extend the flight range of the aircraft and allow for additional time on station. Marshall supplies the tanks in ship-sets of six, along with a number of components. With over 1,100 tanks produced to date, we have achieved an uninterrupted 100% on-time delivery record and 100% quality performance for over a decade.

The certified dual-wall aluminium honeycomb structure we use for our P-8 tanks is a cost-effective solution that maximises strength and reliability while also providing very competitive weight-to-fuel volume performance. Our tank designs offer a 15% increase in fuel volume compared to conventional bladder solutions, while also requiring less frequent maintenance.

We are constantly embedding continuous improvement into our processes and using of new materials such as composite solutions to expand the capabilities of our fuel tanks and systems.

“Marshall is one of the historic names in the UK aerospace industry and a long-term partner of Boeing, developing and delivering the latest in aviation technology right here in Cambridge, serving multiple nations around the world.”

Steve Burnell

Boeing Defence UK Managing Director

Aerial refuelling probes

Marshall has extensive experience providing fixed-mast receiver probes for aerial refuelling on a variety of civil and military aircraft types, including the Lockheed L1011 Tristar, Embraer 145, and Lockheed Martin C-130K Mk1/Mk3 and C-130J. These are simple, reliable additions to the aircraft with minimal maintenance requirements.

As the sole supplier of aerial refuelling probes for the C-130J, we carry out design, analysis and manufacturing in house, delivering completed probes - along with in-fuselage centre-wing connection kits - to Lockheed Martin’s final assembly line in Marietta. These probes are already installed on the German, Italian, Indian and Australian C-130J fleets, and can be supported on all non-US operated C-130J aircraft.

Aerial refuelling probe modifications we offer:
- Refuelling MA-2 nozzle
- Refuelling mast
- Inner refuel line
- Purge line
- Mass balance installation
- Weak link (for safety in case of separation failure)
- Breakaway/shut-off valve
- Metal or composite fairing manufacture and integration
- Structural mounting and fuselage reinforcement
- Nozzle illumination - installation of day- and night-compatible lighting
- Flame arrestor/isolator for lightning protection
- Fuel and moisture drainage
- Cockpit panel modification to accommodate aerial refuelling operation
- Avionic and control logic integration
- In-fuselage dual-wall system installation

We can also design aerial refuelling probes to be removable, reducing drag and lowering the weight penalty when they are not needed.

Through-life support

We meet our through-life commitments with a Continued Airworthiness Management Programme that provides the evidence needed to underwrite safe operation throughout the life of a component or structure.

We have the experience and capability to produce, procure and test spares at both platform and system level, drawing on our in-house production expertise and mature global supply chain.

We can undertake all aspects of component repair and refurbishment, with all repairs designed to maintain airworthiness and structural integrity while reducing fatigue.

Supply chain management

We manage the global supply chain for our advanced structures and components, leveraging our long-term relationships with equipment and material OEMs to provide the required expertise at the right time in the right place.

Our supply chain processes are audited to AS9100 standard and our extensive knowledge of export regulations, including ITAR, helps ensure we maintain a compliant, sustainable and socially responsible procurement process.

We offer extensive warehouse and distribution services, with our warehouse team undertaking all goods receipts, inspection, storage and handling of parts, including dangerous goods.