New Source Corporation increasingly supports major helicopter programs by supplying high-quality aluminum extrusions essential to aircraft performance.
“Extrusions form the backbone of our product line, especially for military and commercial aircraft programs,” said Jamie Barron, Vice President of New Source Corporation.
“Our extensive cross-referencing and certifications allow us to meet a wide range of specifications and part numbers. This versatility means many of our parts serve multiple functions across various helicopter models.”
As a result, New Source Corporation has gradually expanded the number of prime manufacturers that it works with for helicopter programs. “We’ve expanded our product line to cater not only to airplane programs but also to the growing demand for helicopter extrusions,” Barron said.
New Source Corporation’s helicopter manufacturer clients now include Boeing, Bell Flights, Sikorsky Aircraft and others. Here are some of the key models that we support.
AH-64 Apache
Beginning with the AH-64A in 1984, Boeing’s Apache has become known as one of the world’s leading attack helicopters. Today’s AH-64E helicopter is no exception.
Boeing describes the AH-64E as “the most modern configuration of the Apache.” The manufacturer also notes, “With the AH-64E in production until at least 2028, the Apache will serve the U.S. Army and its partner nations as the world’s primary attack helicopter into the 2060s.“
Poland recently became the 19th nation to acquire the Apache and the largest operator outside of the U.S. The country has ordered 96 helicopters.
Australia also recently announced an order. It will acquire 29 AH-64E helicopters with deliveries expected to begin in late 2025.
CH-47 Chinook
Another helicopter manufactured by Boeing, the H-47 Chinook is a heavy-lift helicopter used by the U.S. Army, U.S. Army Reserve, National Guard and 20 countries, including Canada, the United Kingdom, Netherlands, Japan, Italy, Greece, Spain, South Korea, Australia, Türkiye and the United Arab Emirates.
According to Boeing, “It is an advanced, multi-mission, tandem rotor helicopter, proven in cargo and troop transport, search and rescue, casualty evacuation, special operations, humanitarian and disaster relief, and more.”
The U.S. Army took delivery of the first modernized example of the twin-rotor CH-47F Chinook, the Chinook Block II, in July. Boeing’s target CH-47 production rate is 30 to 36 aircraft annually, including all three variants currently being assembled, according to FlightGlobal.
Boeing recently offered the Chinook Block II to Poland to serve as a force multiplier when operating with Apache helicopters.
CH-53 Super Stallion
Manufactured by Sikorsky, a Lockheed Martin company, the CH-53E Super Stallion is renowned for its ability to transport heavy equipment and supplies for amphibious assault missions. Used by Marines around the world, it can take off carrying 16 tons of cargo and deliver it 50 miles away before returning to base.
In August 2023, the U.S. Navy awarded its largest contract yet for the CH-53K King Stallion heavy-lift helicopter program, with a $2.77 billion contract for 35 aircraft. The contract with Sikorsky covers 12 lot 7 and 15 lot 8 aircraft for the U.S. Marine Corps, as well as eight aircraft for the Israeli Air Force. Sikorsky will begin delivering the helicopters in 2026.
The U.S. Navy declared Full Rate Production for the CH-53K program in December 2022, with production expected to increase to more than 20 helicopters annually in the coming years. Sikorsky is procuring long-lead items and critical materials to support the ramp-up of CH-53K production in its digital factory.
UH-60 Black Hawk
Also manufactured by Sikorsky, the Black Hawk is among the world’s most versatile utility helicopters with strong international demand. With 4,000 flying worldwide in 36 countries and 15 million flight hours, including over 5 million combat hours, it’s expected to be flown by the U.S. Army and its allies for decades to come. Its international reach is evident in recently announced deals.
For example, Croatia has tripled its Black Hawk fleet, buying eight additional UH-60M Black Hawk helicopters to give the country a total of 12. Sikorsky also won a $251 million Black Hawk helicopter deal with Jordan and Croatia. Work will be performed in Stratford, Conn., with an estimated completion date of June 30, 2027.
Additionally, in June of this year, two of the U.S. Army’s T901 Improved Turbine Engines (ITE) arrived at Sikorsky, signaling a new phase of Black Hawk helicopter modernization efforts. The T901 engine, which is manufactured by GE Aerospace, will increase the UH-60M Black Hawk helicopter’s performance, including lift capability and range, providing Army commanders more options for planning and executing missions.
Together, these four major helicopter programs are driving New Source Corporation to expand its extrusion line. “Looking at the build rates and the anticipated forecasts of these programs, we want to make sure that we’re in a prime position to not only support the end users that are building these helicopters but also our subcontractors like machine shops that are making the parts,” Barron said.
“With extrusion lead times being how they are, and with our current allocation agreements and the scarcity of extrusions in general, we want to have these available on the floor and ready at a moment’s notice to be able to supply each of these programs,” he continued.
Satisfied customers have referred other companies to New Source Corporation. “They’re coming to us for these helicopter programs. And then, in addition to that, they’re coming to us for our other aircraft extrusions, too, which is great because they previously didn’t even know about us.
“So, our involvement in these helicopter programs is opening new doors, allowing us to support a broader range of projects. It’s the perfect example of how our capabilities are expanding alongside our customers’ needs,” Barron said.
As New Source Corporation grows, we remain committed to anticipating the evolving needs of these and other critical helicopter programs, ensuring we are always ready to provide innovative solutions when they are needed most.
Contact us today to learn how we can help you with aerospace aluminum extrusions or other materials for your helicopter or airplane program.