Aluminum shaft components: Stability and precision in defense technology

Shafts and shaft components are central components of modern weapon systems. They not only provide the outer shape, but also perform important structural and functional tasks—from secure support and precise guidance to the integration of additional modules.

In defense technology in particular, these components must be lightweight, stable, durable, and precisely fitting. This is where aluminum shows its strengths—especially when it is processed using the drop forging method.

KAISER Aluminium-Umformtechnik supports manufacturers and system providers in the implementation of such shaft components – exclusively on the basis of drawings, 3D data, and specifications, or in joint development with the client.

Aluminum as a material for shaft systems

Aluminum combines properties that make it ideal for shaft components:

• lightweight construction: Low weight increases mobility during use.

   

• High strength: Particularly due to the directional grain structure during forging.

   

• Corrosion resistant: Durable even under extreme environmental conditions.

   

• Easy to work with: CNC machining enables precise tolerances and interfaces.

   

• Recyclable: Fully recyclable, without loss of quality.

   

Through drop forging additional costs are incurred dimensionally stable and fatigue-resistant components – a clear advantage over cast or milled parts.

Typical shaft components – always custom-made

KAISER does not offer standardized shaft parts on the market. Instead, we manufacture exclusively to customer specifications. Typical areas of application for aluminum forgings in shaft systems are:

• Shaft bases and support elements – Structural base bodies for modular systems.

   

• Connecting elements – Interfaces between shaft and housing.

   

• Reinforcements – Components that absorb loads from shot dynamics.

   

• Assembly interfaces – for optics, additional modules, or mountings.

   

These components are individually developed, manufactured, and refined as desired—for example, with hard anodized surfaces for increased corrosion and wear resistance.

No standard solutions—with the exception of the AR-15 housing

While all shaft and structural components at KAISER are manufactured specifically for each project according to customer specifications, one component is an exception: the AR-15 housing (upper and lower receiver).

This forging model is the only standardized component in the portfolio and was developed to give smaller manufacturers access to high-quality aluminum forgings—without the high investment costs of purchasing their own dies.

Manufacturing technology at KAISER

The implementation of shaft components involves several precise process steps:

• Drop forging with aligned fiber structure for maximum strength.

   

• CNC finishing to ensure the tightest tolerances.

   

• surface finishing (e.g., anodizing, powder coating) according to customer specifications.

   

• Documentation & Quality Assurance for defense technology standards.

   

This results in components that meet the highest standards of Dimensional stability, resilience, and reproducibility are sufficient.

Conclusion: Aluminum stocks with precision and responsibility

Shaft components are not only shaping elements, but also load-bearing and functional elements of military systems. Using aluminum as a material and the drop forging process as a technology, components can be manufactured that are lightweight, robust, and durable.

KAISER Aluminium-Umformtechnik manufactures such parts exclusively to customer specifications or in close cooperation with the OEM – individually, precisely, and responsibly.

No standard, no compromise – forged part for forged part.