ZRAT is a company specialising in the provision of manufacturing solutions for components of aerospace fluid systems. The production of high-reliability tubing systems is a key focus of the company, with these systems being utilised in a variety of aircraft and aero-engine applications, in addition to other advanced equipment.
The company's capabilities encompass the manufacturing of tube fittings, rigid tubing assemblies and fluid distribution components. These are produced by means of a combination of precision machining, tube forming, special processes and functional testing, all of which take place within an integrated manufacturing environment.
These capabilities enable the provision of both build-to-print manufacturing and engineering collaboration for complex aerospace tubing applications.
The company's manufacturing capabilities extend to a wide range of components employed in aerospace fluid distribution systems, including:
The range of products offered includes straight, elbow, tee and cross configurations of tube fittings
As well as precision-machined connectors and adapters.
Rigid tube assemblies
Flexible hose assemblies
Fluid distribution manifolds
Fuel and lubrication nozzles
Custom fluid system components
The company's production experience is particularly strong in tube fittings and tubing assemblies, which represent the most widely used components in aerospace fluid systems.
The manufacturing capabilities of the company support a broad range of tubing configurations used in demanding aerospace environments.
Typical capability range includes:
Tube diameter range: ∅3 mm – ∅90 mm
High-pressure tubing systems capable of 5000 psi and above
The fabrication of complex tube geometries is achieved through the utilisation of CNC tube bending and precision forming processes.
These capabilities are conducive to applications where structural integrity, sealing reliability and pressure performance are of paramount importance.
It is asserted that a variety of aerospace tubing connection technologies are supported, thereby ensuring compatibility with differing system architectures.
Available connection methods include:
Beam-type metal seal connections
Radial swaging connections
Axial swaging connections
Crimped hose connections
Flared fittings
Welded tube assemblies
These connection methods are widely utilised in high-reliability aerospace fluid systems, where leak-tight sealing and long-term durability are paramount.
Tubing system components are manufactured using a range of aerospace-grade metallic materials, including:
Stainless steels
Aluminum alloys
Titanium alloys
Nickel-based alloys
Other aerospace metals specified by customers
Among these, steel, aluminum and titanium alloys represent the most frequently used materials across current production programs.
The engineering team is responsible for both build-to-print production and the development of collaborative manufacturing processes.
Typical support activities include:
Manufacturing process development
Prototype and sample production
Tube forming and machining process optimization
Transition from development to serial production
This approach facilitates efficient support from the project's inception through to its stable production programmes.
A laboratory that has been accredited by the CNAS (Committee on National Accreditation Standards) is able to conduct functional testing of tubing system components with a view to verifying their performance and reliability.
Testing capabilities include:
Pressure testing
Leak testing
Burst testing
Fatigue testing
Salt spray testing
Repeated assembly testing
Further specialised testing, including lightning strike and fire resistance testing, can be conducted through qualified partner laboratories.
The utilisation of tubing system components is prevalent in a multitude of challenging fluid systems, encompassing the following:
Fuel systems
Hydraulic systems
Lubrication systems
Pneumatic systems
Environmental control systems
Brake systems
Applications extend across multiple sectors such as:
Aerospace
Space systems
Aero-engines
Rail transportation
