Marshall wins 14 year contract from Thales to produce sonar modules for Royal Navy
Marshall has received a long-term contract from Thales UK to manufacture, maintain and support key …
Complex subsystem assembly
Marshall is a globally respected provider of complex subsystems engineered to meet the toughest 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 platform-agnostic capabilities. Our NADCAP-accredited engineering team includes structural, electrical, interior, integration, systems, stress, weight, aerodynamics and avionics designers.
Our advanced manufacturing and co-production facility 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 the requirements, we take projects all the way from specification and design through to manufacturing, testing, qualification, integration and through-life support.
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. As Boeing’s exclusive supplier of auxiliary fuel tanks for the globally successful P-8 Poseidon maritime patrol aircraft since 2005, Marshall has applied its design, engineering and manufacturing capabilities to deliver a market-leading lightweight fuel system solution. Current operators of the P-8 now include the United Kingdom, United States, Australia, Germany, India, New Zealand, Norway and South Korea.
Production of auxiliary fuel tanks
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 1,200 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
Submarine structures
Marshall manufactures, maintains and supports key components of anti-submarine sonar arrays under a long-term contract from Thales UK, providing a critical edge for the UK’s Royal Navy.
We are proud of our position as a leading supplier for two of Thales’ most advanced sonar suites, Sonar 2076 and Sonar 2087. The former is equipped on Astute class submarines in addition to the next-generation Dreadnought class, while the latter is in use on existing Type 23 frigates and will also be equipped on their upcoming replacement, the Type 26, including variants for export.
Production and in-service support is undertaken by Marshall’s Advanced Manufacturing Solutions business line in Cambridge, UK.
“We are delighted to award Marshall a prominent role in our supply chain for the world’s most advanced sonar suites in recognition of their outstanding technical capabilities and exemplary level of support for flagship UK defence programmes.
“Our collaboration with supply chain partners like Marshall is critical to the continued success of Thales and the Royal Navy’s Maritime Sensor Enhancement Team (MSET) programme, delivering round the clock equipment availability and resilience.”
Steven Lockley
Managing Director, Underwater Systems, Thales UK
Built to withstand the extremes of an undersea operating environment, our structures are corrosion-resistant, giving them increased durability and enabling them to last extended periods of time in a saltwater.
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 on Lockheed Martin C-130
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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.
