Session D1 Osman Okyay

KALE AEROSPACE & DEFENCE 

“Turkish Defense Industry as a Best Value Partner” 

June 12th, 2012 - Washington DC 

Osman Okyay 

President, Technical Division, Kale Group, Turkey 

Chairman, Aerospace Clustering Association 

Kale Proprietary Information 

1

Partnership Programs – Opportunities 

To take part in the global supply chains 

Opportunity to become a longer term supplier to the US 

Prime Contractors 

Growth through new work packages 

Technology Transfer Opportunities 

Reference in qualifying for other global programs 

Kale Proprietary Information 2

Partnership Programs – Challenges 

US Prime Defense Contractors not only require local 

companies to meet certain contract standards for price, 

quality, and delivery, but also demand stringent 

regulations like ITAR as well as higher data security and 

IT standards for military programs in order to get 

qualified 

In most cases, local subcontractors are asked to meet 

the same contract standards as qualified home country 

subcontractors that have been in the business for a long 

time (no learning curve allowed…) 

Challenges on program schedules and volumes 


Key Elements for Success 

Understanding the needs – CUSTOMER CTQ’s 

Understanding the rules and regulations 

Competitiveness through innovation 

Ensure two way communication 

Speaking the same language 

Building mutual trust 

Being open – Sharing what can and what cannot be 

done 

Target for a win-win 


KALE GROUP 

Established in 1957 

Activity areas: Building Materials, Mining, 

Transportation, Aerospace & Defense 

Turnover: 1Bn USD 

No. of employees: 5,000+ 


KALE GROUP – Aerospace & Defense 

KALE Group 

Aerospace & Defense 

Kale Kalip 

Kale Baykar 

Kale Aerospace 

Kale 

Pratt & Whitney 

1969 2006 2007 2011 


6

1969 – 1989 

Kale Kalip – started as a die and mold shop to support its 

tile production, only. 

No defense work planned at the beginning. 


1989 – Turning Point... 

EURO-STINGER PROJECT 

In 1987, Turkey participated in 

Joint Production Project of 

Euro-Stinger Missiles 

In 1989 Kale Kalip 

participated 

Project duration: 1989 - 2004 

Total of 22 work packages 

Missile guidance control 

capsule. 

Fin assembly 

Battery cooling unit 

Launch motor case 


RAPIER MISSILE PROJECT 

Rapier MKII missile 

Turkey-UK Coproduction Program 

1997-2007 


LM MISSILES & FIRE CONTROL 

It all started with a $ 50 K initial 

order. 

Big challenge to sell a missile part 

to the US that was “Made in 

Turkey.” 


KALE KALIP 

TODAY 


CAPABILITIES & PROJECTS 

Small Arms And Rocket Launchers Design & 

Manufacturing 

Special Tools, Dies & Molds Design and Manufacturing 

Projects: 

• Design & Development of New Turkish Infantry Rifle 

• Design & Development of New Turkish Light Machine 

Gun 

• Manufacturing of AGL (Automatic Grenade Launchers) 

• Design & Manufacturing of various Rocket Launchers 


Combat Rifles 

• 7,62 – 5,56 

• 3.9kg - 3,2kg 

• NATO 4694 Piccatiny 

• Full and Semi Auto 

• Gas Piston 

• Rotating Bolt 

• 20-30 Ammo Mag 

• Free Float Barrel 

• Rate of Fire : 600 RPM 

• Effective Range : 400m 


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308 & 338 Sniper Rifles 

• Free Float Barrel 

• Composite Stabilizer 

• Adjustable trigger 

• Adjustable Cheek Pcs 

• 360 Swivle Stock 

• 5.70 kg, 

• 5 - 10 Mag 

• 12’’ : 1 Barrel 

• 1,200 m Effective Range 


14

Light Machine Gun – LMG 

• 7,62 – 5,56 

• Rate of Fire : 750 - 600 

RPM 

• NATO 4694 Rail 

• Gas Piston 

• Rotating Bolt lock 

• Weight : 4,8kg - 6.3 kg 

• Belt Feed 


15

Automatic Grenade Launchers 

40 mm AGL 

Design & Manufacturing 

• 360 grenade/min 

• 34 kg 

• HV/HP 

• 1,700 m effective range 

• 2,200 m range 

40 mm Heli / Vehicle AGL 

• 500 grenade/min 

• 1,700 m effective range 

• 2,200 m max range 


16

122 mm-302mm MLRS 


Launchers, developed by 

KALEKALIP, now in Turkish 

Armed Force (TAF ) 

inventory 

Extended range capability 

Design and manufacturing of 

122 mm. Rocket Nozzle and 

Fins 

Leading to development of 

best in class product design 

capabilities with our own 

know-how. 

Currently upgrading 

Launcher Canisters for the 

KSA Armed Forces together 

with MKEK 

17

KALE AEROSPACE 


General 

Established in 2008 in the Free Trade Zone, Istanbul 

Over 1 Million Hours of Engineering 

Total shop floor 15,000 sqm 

Number of Employees : 240 


19

Core Business & Activities 

Manufacturing 

Complex Aero-Structures 

Fuselage Parts– Wing Parts, 

Assemblies & Components 

Design – Manufacture – R&D 

Civilian Aerospace 

Military Aerospace 

Defense 


20

Capabililities 

Engineering; Catia, Unigraphics, Vericut 

Complex 3-5 axis milling, 2-9 axis Turn/mill 

Sheet Metal Aero Structures and Assemblies 

Tool / Die Design & Fixture Manufacturing 

In House Special Processes (Nadcap) 

In House NDT/DT (Nadcap) 

In House Vac./Conven. Heat Treat, Gas Nitride 

Painting / UID Marking 

Shot Peening / Auto Blasting 

Welding MIG-TIG, AWS Approved Lab. 

Latest Tech Inspection Lab. 


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Projects 

Projects : 

• F-35, Structural Parts 

• Boeing 787-777-737 Structural-Fabrication Parts & Assy’s 

• Airbus 319-320-321 Center Fuselage Fuel Tank Parts 

• Korean Utility Helicopter – Structural Parts & Assy’s 

• GMLRS/ATACMS Parts 

• Awacs Ground Support Equipment 


Quality 

Lockheed Martin Star Supplier 

AQAP 2120 NATO Certification 

AS/EN 9100 

NADCAP Approvals 

Six Sigma Applications 


Customers 

HEROUX DEVTEK 

● 

SPIRIT 

BOEING ● ● 

● LOCKHEED MARTIN 

● 

NORTHROP GRUMMAN 

AIRBUS 

● 

KAI 

● 


Kale Aerospace – JSF Program 

KALE AEROSPACE 

‘’JSF PROGRAM’’ 


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F – 35 

Kale Aero is one of the 

major partners of F-35 

LM Aero Structural parts 

Northrop Grumman Structural parts 

Uplocks with Heroux Devtek, Canada 


F – 35 LM Aeronautics 

238 Part Numbers Awarded Long Term Single Source 

Wing, Forward Fuselage and Cockpit Components 

Mid–Large Size Complex 5 Axis Parts & Assy’s 

Fracture Critical, Maintenance Critical, and Fuel Tank, 

Parts 


F – 35 LM Aeronautics 


F – 35 Northrop Grumman 

43 Part Numbers Awarded Long Term 

Center Fuselage Components & Sub-Assy’s 

Small–Mid Size Complex 5 Axis Parts & Assy’s 

Fracture Critical, Maintenance Critical and Fuel 

Tank Parts 


F – 35 Northrop Grumman 

Center Fuselage 5 Axis Parts 


F – 35 Uplocks, Heroux Devtek 

Kale participated in the SDD phase 

Design & Manufacturability 

5 different uplocks for 3 F-35 variants 

11 Uplocks per Aircraft 

47 Part Numbers & Assemblies 


Boeing – Auburn Program 

Structural Parts 

and Assemblies 

for 

B-737 

B-777 

B-747 

B-747-8 

Sole Source on 400 Part 

Numbers 

60,000 pieces shipped 

annually 


Sprit Aerosystems, B - 777 

Pylon Assembly Components and Sub Assemblies 

20 Different Assy’s, 1,550 Units per year 


Boeing, B – 787 Project 

Participated in Design & Manufacturability 

Parts Manufacturing – Bearing & Bushing Assy. 

Horizontal Stabilizer Parts 


Fuel Tank Parts - Airbus 

17 Center Fuselage Fuel Tank 

Part Numbers 

7 Different Tanks for A319, 

A320, A321 


Turbojet Engine Design 

Kale Aero has been 

awarded the 

contract by SSM to 

design and develop 

an indigenous 

Turbojet Engine for 

Turkish SOM Missile 


KALE PRATT & WHITNEY 


Kale Pratt & Whitney 

 

 

 

 

J/V between 

Kale Group and 

Pratt & Whitney 

Critical aircraft 

engine parts 

mainly for F 135 

60+ Mio USD 

investment (1 st 

phase) 

Facility to be 

located on a 

100,000 sqm 

land, in Izmir 

ESBAS Free 

Trade Zone 

(Operational in 

Dec. 2012) 


KALEBAYKAR 

KALE – BAYKAR 

“Future is Unmanned...” 


UAV Systems 

KALEBAYKAR 

Kale – Baykar JV 

Indigenous Design and 

Manufacturing of UAV 

Systems 

Mini Class: Fixed wing 

and VTOL Systems 

Mini UAV Systems in TAF 

inventory since 2007 

Tactical UAV Systems in 

production and planned to 

be in the TAF Inventory by 

mid 2013 


40

UAV Systems 

KALEBAYKAR 

UAV 

STATUS 

Fixed Wing 

Mini UAV System 

In Production 

VTOL 

Mini UAV System 

In Production 

Tactical VTOL 

UAV System 

R & D Phase 

Tactical Fixed Wing UAV 

System 

Prototype Phase Developed, Successfully 

Tested, in Production 


41

Fixed Wing Mini UAV: Specifications KALEBAYKAR 

Range: 15+ Km 

Cruise Speed: 55 Km/hour 

Operational Altitude: 2,000+ feet 

Maximum Altitude: 12,000 feet 

Endurance: 60 Minutes 

Take Off / Landing: Hand Launch / Parachute or Belly Landing 

Outside Working 

Temperature: 

(Fully Automatic) 

Power: Brushless Electric Motor 

-20C , +55 C 

Wind Speed Limit: 25 Km/hour 

Noise Signature: 0 – 200 m 


KALEBAYKAR 

Fixed Wing Mini UAV: Advanced Features 

• Automatic Return and Landing in case of lost communication or 

critical sensor failure 

• Smart battery management system 

• Dead Reckoning Capability Without GPS 

• Automatic Spin Recovery Feature in High and Harsh Wind 

Conditions 

• Automatic Stall Recovery in case electric motor malfunction 

• Very Advanced Ergonomic User Interface 

• Advanced Video Analysis and Control Functions During Flight 

• Real Time Google Earth Integration and 3D Visualization of Plane, 

Routes, GCS etc. 

• Ground Control Switching Capability 

• TCP/IP Remote Connection to Operator Interface and Real Time 

Command, Control And Monitoring 


“Combat Proven” 


Gas Powered VTOL UAV Systems 

Specs. 

Rotor Span: 

Endurance: 

Range: 

Max Altitude: 

Operational Altitude: 

Power: 

Fuel: 

1.8 m 

80 Min 

15 Km 

10,000 ft 

3,000 ft 

Internal 

Combustion 

Engine 

Gasoline 


45

Electric Powered VTOL UAV Systems 

Specs. 

Rotor Span: 

Endurance: 

Range: 

Max Altitude: 

Operational Altitude: 

Power: 

Fuel: 

1.8 m 

35 Min 

10 Km 

10,000 ft 

3,000 ft 

Electric Motor 

Battery 


46

Ground Control Systems 

Auto Tracking Antenna Unit 

Ground Control Unit 

Ground Data Terminal 


47

Tactical UAV Systems 

Specs. 

Total Weight: 475 kg 

Payload Capacity: 40 kg 

Operational Altitude: 18,000 Feet 

Endurance: 10 Hours 

Cruise Speed: 125 Km / Hr 

Wing Span: 9 m 

Length: 5.6 m 

Power: Internal 

Combustion 

Fuel: Gasoline 

“FULL AUTOPILOT TAKE-OFF, LANDING AND FLIGHT” 


48

Tactical UAV Command Control 


49


First Demo Flight in October ’09 

Max. Altitude: 19,000 ft. 

Duration: 10 hours 

Fully AtuonomousTake-off, Landing and Flight (even Taxi on the ground) 


Partnership Programs 

are enablers in creating 

the opportunity to 

integrate local Turkish 

companies to US Prime 

Contractors and 

Turkish Defense Industry 

provides best value to its 

partners. 


Thank You...

Session D1 Osman Okyay

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