Challenge
A major aero-engine OEM faced significant manufacturing inefficiencies with their existing bearing housing design. The component featured 48 welded cast vanes, resulting in an unnecessarily complex assembly process that increased production costs and time. In an industry where the quality of every component affects operational efficiency, this suboptimal design needed urgent optimization.
Solution
Quest Global delivered an optimized bearing housing design that:
- Implemented single-piece casting architecture to replace the complex 48-vane assembly
- Validated structural integrity through comprehensive analysis aligned with OEM standards
- Developed complete design documentation, including stress analysis and engineering drawings
- Reduced aerodynamic wind steps in the annulus to enhance performance
- Created manufacturing guidelines to ensure consistent production quality
Results – At A Glance
- Achieved 50% reduction in manufacturing costs
- Decreased component weight by 23%
- Improved aircraft fuel efficiency through enhanced aerodynamics
- Met all redesign requirements 100% on-time and on-budget
- Delivered all redesign requirements on schedule and within budget
- Provided complete documentation package, including 3D models, stress reports, and manufacturing specifications
Chris Hardgrave joined Quest Defense in April 2024 as Vice President for Strategic Accounts. He is responsible for sales, growth, and development of strategic relationships for new business development efforts in the Aerospace and Defense sector. Chris works in the Washington, D.C. office.
As Chief Engineer for Quest Defense, Jon is responsible for ensuring that sound engineering processes are maintained and followed by our employees working in a diverse set of services and disciplines across all verticals. In this role he also leads Quest Defense’s efforts to develop new methods and technologies to help grow the business through innovation, as well as building and promoting the technical reputation of the company in the public sphere.
Jeff Fischer serves as a board member for Quest Defense Systems and Solutions business. Additionally Jeff is the Operations Leader for the Quest Global Aerospace and Defense Industry.
Steve Gerber is President and CEO of QuEST Defense Systems and Solutions business and is responsible for providing the leadership and growth of this venture.
Joe supports Special Missions across Quest Global to include key client contract negotiations, strategic business solutions, M&A, and culture endeavors.
Frank Kendall is an independent consultant to defense industry firms and non profit research organizations. He is a Senior Fellow at the Center for American Progress, a Senior Advisor to the Center for Strategic and International Studies, and a member of th e Council on Foreign Relations. Among other industry positions, he is a member of the board of directors of Leidos Corporation and of Leonardo Electronics USA Inc. From 2012 to 2017, Mr. Kendall served as the Under Secretary of Defense for Acquisition, T echnology and Logistics (AT& after serving as the Principal Deputy Under Secretary from 2010 2012. Mr. Kendall has over 45 years of experience in engineering, management, defense acquisition, and national security affairs in private industry, governmen t, and the military.
John Thackrah is the founding Principal of Sextant Solutions LLC, an aerospace, maritime and government acquisition consultant.
Page Hoeper is a private consultant, corporate director, and venture capitalist. Since leaving government service, Mr. Hoeper has focused on corporate governance and board service. He chairs the boards of OnPoint Technologies, Inc., 501c(3) venture capital fund established by Congress to focus on emerging commercial technologies of interest to the U.S. Army, and Quest Defense Systems & Solutions, a provider of engineering services to the U.S. defense industry.
As the President of Quest Global, Bob is responsible for establishing and maintaining senior customer relationships, catalysing new business development, and overseeing innovative and transformational deals. In this role, he also assists in building relationships with strategic acquisitions for the company.