Greater Testing Needed to Meet Stronger Aerospace Safety Demands

Q: What specific challenges do Element's aerospace industry clients face, and what are the main problems you help them solve with testing and inspections?

A: Our main clients in Mexico forge components for aircraft turbines, and one of their main challenges is preparing for the increase in business activities driven by nearshoring. The aerospace industry has significantly benefited from nearshoring, which has led to more aggressive growth than expected. The entire supply chain faces a challenge in meeting delivery timelines and demands from Original Equipment Manufacturers (OEMs). The supply chain also needs more technicians. Element aims to develop its own talent because it is difficult to find specialized labor at the local and national level. 

Q: Which of Element’s services are in higher demand?

A: Element offers a wide variety of services. Globally, Element is the top global provider of material testing services. We have almost 300 laboratories around the world, more than 120 in the Americas, and one in Mexico, but the company plans to expand in the country. Element’s offices in Monterrey, Nuevo Leon, focus on the aerospace industry and can perform both destructive and non-destructive testing on materials, especially metals. 

Non-destructive testing has seen the highest increase in demand due to the growth of the industry, but we have also seen a smaller increase in the demand for destructive tests, such as fatigue or fracture tests. 

Q: What are the main benefits of the company’s non-destructive tests?

A: We offer several non-destructive tests, such as immersion ultrasonics, fluorescent penetrant inspection (FPI), and macroetching. Among these techniques, immersion ultrasonics is the most complex and has presented the greatest challenges. It allows for the internal analysis of a component to detect volumetric discontinuities. It is crucial for ensuring the internal integrity of components, which is a vital process in the aerospace industry due to its high safety and performance standards.

The main challenge in performing immersion ultrasonics is finding qualified technicians to perform these inspections. The demand has increased significantly and training technicians in this technique is not straightforward. Element has had to develop its own technicians.

Q: What capabilities and technologies make Element unique and position it as a leader in the field?

A: Element Monterrey has a comprehensive range of accreditations essential for the aerospace industry. The entire laboratory has the NADCAP and ISO 17025 certifications, which are indispensable for operating in the aerospace sector. It also has approvals from Boeing, Honeywell, and Rolls Royce, among others, which establish us as a leading player both nationally and internationally.

Element achieves global leadership through its extensive network of global laboratories. This network enables us to handle large projects. We conduct 90% of tests in Monterrey and the remaining 10% in other laboratories within our network.

Q: How has Element performed in Mexico over the past year?

A: Element's performance in Mexico has been significantly better than anticipated. We grew nearly 80% in sales in 2023 in comparison to 2022. This growth has been largely driven by high demand due to nearshoring. We also increased our workforce by 80% and made large investments in new equipment. We continue to work on acquiring more equipment and expanding our services to ensure we have the necessary capacity to meet both current and future demand. 

Element leverages a global team of over 10,000 to collaborate, develop new projects, tackle challenges, and ensure technical knowledge is maintained across our sites. This technical strength is one of our greatest advantages. 

Q: What new tools or methodologies is Element implementing?

A: Last year, Element’s IT team launched an internally developed operating system, and our facilities in Monterrey pioneered the adoption of this software. This new platform is more flexible than the previous one as it does not require a VPN. We are also advancing projects aimed at enhancing efficiency through Industry 4.0 initiatives, using tools such as the Internet of Things (IoT) and black box systems. These tools provide us with detailed real-time information, improving decision-making and enabling us to be proactive rather than reactive.

Q: What practices does Element use to support sustainable production, and reduce consumption and carbon footprint?

A: Since testing itself is not resource-intensive, our sustainability efforts focus on secondary activities. Across the corporation, we have a program to measure our carbon footprint and energy consumption. The first stage involves measurements to assess individual laboratory contributions, followed by various projects to address these findings. This year, we will start analyzing the installation of solar panels at our facilities. We also acquired an 18-ton truck with environmentally friendly technology that uses a chemical to reduce its carbon footprint. 

Q: How is Element adapting its testing services to accommodate new materials? 

A: The aerospace industry requires materials to undergo extensive research and testing materials before being used in operations. We are observing that, while the fundamental tests remain similar, they are conducted under more extreme conditions. For example, a fracture test that used to be conducted at 650°C may now require higher temperatures, such as 700°C. We have clients manufacturing components for rocket launchers who request impact tests at extremely low temperatures, down to -200°C. This necessitates changes in cooling techniques and the adaptation of our processes.

While our primary focus is on metals, we also entered the composite materials market, which requires similar tests. Inspections often follow similar principles, with minor adjustments to conduct the tests effectively.

Q: How does Element develop tests according to the client’s needs?

A: Element collaborates closely with developers and researchers. We have been involved in developing non-destructive testing techniques, primarily in the United States. On several occasions, clients have requested the development of new, specific tests. Element has played a crucial role in these developments, acting as a primary bridge for clients needing new testing techniques.

Q: What is driving the increased demand in non-destructive testing techniques, and how is Element innovating to offer these new options?

A: The demand for non-destructive testing has risen due to the requirements of our end clients, particularly in terms of safety and quality assurance. Unlike destructive testing, which involves damaging the material to assess its strength, non-destructive testing allows us to examine components without altering their integrity, ensuring their functionality and longevity. This increase in demand is driven by the growing complexity of designs and the corresponding need for higher quality assurance. Volumetric testing, for example, is an advanced technique that enables us to inspect the interior of components to detect hidden defects or irregularities that could affect their performance in operation.

Element has been continuously innovating to meet these new demands. We have developed and enhanced specific non-destructive testing techniques, working closely with clients in the development of new methodologies with R&D institutions. This enables us to offer advanced and customized options that meet the industry's most rigorous standards.

Q: As a service-oriented company, how are you innovating to maintain quality at every stage of the supply chain?

A: Element ensures that what has been designed and developed over years of research meets required specifications and standards. Given recent events in the commercial aerospace industry and the ongoing pursuit of component efficiency, we have observed an increased demand for more complex tests, such as fatigue tests primarily used in validations.

This demand has grown significantly in recent years, reflecting the increasing complexity of components and the need to ensure their functionality. This trend is mirrored in other global laboratories, indicating a focus on comprehensive validation of new developments.

Q: What are Element's strategic priorities for the next three to five years?

A: Our company's motto is "Making Tomorrow Safer Than Today." Since 2022, our ambition has been to double our business by 2025, and all our priorities are aligned with this goal. Our core values are integrity, care, and progress. Integrity is critical in the aerospace industry, and care extends to our employees, customers, and stakeholders. Progress involves innovating and developing new capabilities to maintain our leadership in the industry.

In Mexico, our priority is to increase Element's presence and expand across Latin America, offering new capabilities and remaining the top choice for our customers in all matters related to materials.