Rapid Concept to Production

SAS Manufacturing has vertically integrated as SAS Flight Factory to address the critical and immediate needs of our clients.

As an AS9100D certified company, we are known for high standards of quality, excellence and on time delivery. SAS Flight Factory provides rapid prototyping to production and testing capability. Advanced Manufacturing, including additive manufacturing, bridges the gap between the R&D, prototyping and production. Through our proven services and analysis, SAS provides time-critical solutions to our client’s most demanding schedules, mission critical programs, high-quality parts and precision components, and new business opportunity strategies. Our team consists of highly qualified, industry experts and engineers, machine operators, programmers and quality assurance professionals. We believe that getting it right means incorporating all of the tactics and components of risk into a robust and successful process.

Download SAS Flight Factory Capabilities 

Design for Manufacturing

Our facility specializes in design for manufacturing optimization. SAS Flight Factory has developed seamless workflow between our engineers and manufacturing teams for rapid on-time delivery. SAS Flight Factory's manufacturing design is fully integrated with our tactical engineers at SAS to take a client’s concept and create a prototype in less than a week.


  • Complete CAD/CAM Design
  • Specialized Hardware Design
  • Utilization of Advanced ERP Systems
  • NX, Solidworks, Ansys


Production and Prototype

SAS Flight Factory has received AS9100 and ISO9000 certifications and is equipped with the latest 3D printers, lathes and milling apparatus, including 5-axis computerized numerical control (CNC) device. Highlights include:

  • Designated 3D-Printing Area
  • Complete CAD/CAM Design Capabilities
  • Specialized Hardware Design and Development
  • Complete In-House Quality Control in accordance with AS9100
  • Competitive Product Pricing
  • Implementation of Cost Saving Processes


SAS Flight Factory is capable of precision clean assembly of client components to full systems. Efficient assembly to meet rapid timelines is imperative to our commitment to product excellence and on-time delivery.

  • AS9100 Rev D Assembly
  • Precision Clean
  • Components to Full Systems
  • Secure Facility Capable


As a lifecycle facility, our team provides expertise in a variety of system validation and product quality assurance methods.

  • IAT- Initial Acceptance Testing
  • Integrity, Reliability and Traceability
  • Technical Excellence
  • Proof Pressure Testing