Expedited Sourcing Keeps Critical Test Launch on Schedule
Xometry helped a Tier-1 defense contractor source a complex bill of materials within days, keeping a test flight on schedule and avoiding costly delays.
A leading Tier-1 defense contractor faced a critical challenge: sourcing a large, complex bill of materials (BOM) for an advanced program on an extremely tight deadline. Missing the delivery deadline would mean rescheduling a test flight, resulting in significant delays and cost overruns. The contractor needed a manufacturing partner capable of rapidly scaling qualified production and managing complex logistics to keep the project on schedule.
The Challenge: Critical Deadline for Complex Components
Finding a single supplier that could handle the sheer volume and complexity of the parts proved challenging for the contractor. The BOM comprised a diverse mix of materials and manufacturing processes, including CNC machining and sheet metal cutting. Most suppliers quoted lead times of 1–2 weeks, which was far too long to keep the test launch on schedule. The key obstacles were:
- Urgent timeline: A fixed deadline driven by the test flight schedule.
- Part complexity: 190 unique part numbers and over 1,000 discrete components.
- New parts: Most of the part numbers were new to the supply chain, requiring rapid qualification and production ramp-up.
The Solution: Network Capacity and Process Optimization
The contractor partnered with Xometry to tap into our vast network of manufacturing partners and rigorous quality controls to solve the immediate sourcing crisis. Xometry quickly mobilized dozens of qualified partners and utilized its AS9100 certification to ensure all components met the defense industry's stringent quality standards. The core strategy focused on minimizing wasted time through streamlined project management and intelligent production adjustments. The key strategies for expedited delivery included:
- Massive network capacity: Engaged 44 manufacturing partners simultaneously to absorb the large BOM and reduce load on any single supplier.
- Proactive project management: Tracked every component in real-time, proactively identifying and resolving potential bottlenecks before they impacted the schedule.
- Process efficiency recommendations: Recommended smart adjustments to the manufacturing process, such as eliminating unnecessary finishing requirements to shave valuable days off the lead time.
- Early, incremental shipping: Broke down the large order into smaller quantities, allowing parts to be shipped immediately upon completion rather than waiting for the entire lot.
The Results: On-Time Launch and Long-Term Partnership
Through this expedited, comprehensive approach, Xometry successfully reduced the typical 1–2 week lead times down to 1–2 days for many critical components. This performance ensured the timely delivery of the full BOM, enabling the contractor to proceed with the test flight as planned.
The success of this program led to a long-term relationship with the contractor, resulting in more than 20 new programs. Xometry has proven to be a flexible, quality-driven sourcing partner that can meet the demands of the aerospace and defense industry.