Production & Process Support
At AeroSage Consulting, we specialize in designing and optimizing sealant and adhesive packaging workflows tailored to the rigorous demands of aerospace and high-performance manufacturing. From Semkits® and Techkits® to dual cartridges, bi-paks, and Pre-Mixed and Frozen (PMF) systems, we ensure every process is engineered for precision, compliance, and repeatability.
Workflow Optimization for Complex Chemistries
We help clients streamline packaging and dispensing operations for single- and multi-component materials, with a focus on:
- Selecting the optimal packaging format for material compatibility, pot life, and application method
- Reducing waste and rework through controlled mixing, storage, and dispensing
- Enhancing traceability, shelf life protocols, and lot control across packaging types
Expertise Across Packaging Formats
We support a wide range of aerospace-approved packaging systems, including:
- Semkits® and Techkits® for on-demand mixing and field-ready deployment
- Dual cartridges for precise 2K dispensing in manual or automated systems
- Bi-paks for compact, flexible packaging of reactive materials
- Pre-Mixed and Frozen (PMF) systems for ready-to-use, high-performance applications
Advanced Materials for Specialized Applications
Our process support extends to cutting-edge formulations, including:
- Next-generation sealants featuring lightweight, rapid cure and chromate-free technology for reduced mass, enhanced application efficiency and environmental compliance
- Specialty adhesives designed for avionics, electronics, and sensitive assemblies
- Materials requiring precise thermal management, conductivity, or EMI shielding
Custom Procedures & Work Instructions
Repeatability and compliance start with clear documentation. We develop tailored:
- Standard Operating Procedures (SOPs)
- Work instructions for packaging, thawing, mixing, and dispensing
- Visual aids and training materials to support operator consistency and reduce variability
Compliance-Driven Process Design
Our approach integrates quality and compliance from the ground up:
- Alignment with AS9100, ISO9001, and NADCAP requirements
- OEM-specific packaging, labeling, and documentation protocols
- Audit-ready process validation and continuous improvement support
Cross-Functional Collaboration
With over 35 years of hands-on experience across manufacturing, specialty packaging, and OEM operations, we bridge the gap between engineering, production, and quality teams to deliver practical, scalable solutions.