Metal Bellows & Assemblies

The development process begins by taking the customer’s requirements. Great emphasis is placed upon fully understanding these requirements and the application. The manufacturing process involves a range of activities undertaken by our talented team of engineers, including cold roll forming, elastomeric forming, expanding, sheet metal working, tube manufacture, laser profiling, TIG welding, plasma welding, CNC turning, and more.

All systems and components are put through a rigorous qualification programme to ensure the design meets operational and environmental requirements. The test report is written and signed off by the customer for approval. With our in-house radiography, dye penetrant and pressure test facilities, together with mass spectrometer leak detection and three-axis measuring resource, Senior Bird Bellows is well equipped to perform the complete testing and qualification process.

Our highly experienced team of engineers have found many solutions for challenges presented by bellows assemblies. By taking view of the whole system, we can use our knowledge and experience to recommend the best type and where they should be fitted.

The more involved we are in the process, the more we can utilise our knowledge and experience to optimise the design. This in turn has a positive impact on weight, cost and efficiency.

• Rolls Royce SABRe
• Airbus
• Embraer
• BAE Systems
• Leonardo
• Bell
• GKN
• Dresser
• Honeywell
• Baker Hughes

• Part 21 Subpart G Production Approval – UK CAA
• AS9100 Rev D Quality Systems Aerospace – BSI
• ISO9001
• ISO14001 2015 Environmental Management System- BSI
• Nadcap AS7114 Non Destructive Testing – PRI
• Nadcap AS7110 Welding – PRI

Senior Bird Bellows have adapted a gated New Product Introduction Process, which is based on AS9145. Many OEMs are now beginning to use this process.

We design innovative, cost-effective engineering solutions, specialising in the design of bellows, bellows assemblies, gimbal bellows, flexible joints and aerospace bleed air ducting systems. Our team of experienced engineers cover all parts of the process, from system analysis and concept to detail, qualification and production supply. This enables us to fully optimise the design of the system, using our extensive knowledge and experience to maximise efficiency and minimise weight and cost.

With a production area of 60,000 square feet, our dedicated team of experienced engineers have access to leading technology and resources to create a range of high quality, high performing products to operate in extreme environments and applications. Our fully equipped site houses a wide range of production machinery including; a CNC tube bender, various CNC lathes and machine centres, and robotic spot welding and polishing. Furthermore, our new production process based on AS9145 means we can offer high standard products that are producible and repeatable in a timely manner.

Our thorough material selection process ensures maximum efficiency and safety is achieved for every application. Our scope of materials include: stainless steel, nickel alloys, Hastelloy®, Incoloy® 825, Monel® 400 and titanium Gr.2. The specific selection is based on the requirements of the part and the environment it’ll be based in, including the pressure and temperature levels it will undergo. It is imperative that the right materials are selected for each project, as parts failure is simply not an option.

Our on-site testing and qualification facility is purpose-built and highly adaptable to ensure maximum performance of all our products. Our leading technology enables us to provide extensive testing across all products, meeting the demand for application conditions during product qualification. Typical tests include: endurance at elevated temperature, cyclic fatigue, proof/burst and rupture, 24/7 cycle testing, high temperature and pressure, subzero and icing, helium leak detection, radiography, dye penetrant, air under water, mass spectrometer leak detection and three-axis measuring resource.