Kaelin Aero Technologies

Kaelin Aero Technologies builds and repairs aircraft structures for civil and military customers. It also develops and builds complete aircraft. The group has a base in Germany and a sister company in Switzerland, with sites at Sempach Station and Bioggio near Lugano.

The company's stated goal is to make customers' aircraft ready for use again. The work can be a single part, a rebuild or a new aircraft. In design and development, Kaelin takes a job from the first idea through prototype building to approval, with all steps in house. The team makes CAD models, drawings and parts lists. It uses a 3D scanner for reverse engineering. It also builds tooling, runs analysis and simulation, and handles talks with the aviation authorities. A partner engineering office checks static and dynamic loads for modifications.

Single piece production covers parts for historic and modern aircraft. Kaelin works from design data, sample parts or drawings. In house processes include CNC milling on three and five axes, hydroforming, integral milling and non-destructive testing. The company also offers painting, corrosion protection, aviation welding and heat treatment for aluminium and steel.

Kaelin is an approved supplier to aircraft makers for structural assembly. Examples include doors, control surfaces and landing gear fairings. For Pilatus, it has supplied parts for many years and makes about 330 components a year. Six different parts are now built for the PC-24.

The repair team travels the world to fix damaged wings, engines and landing gear. It also restores historic aircraft. One job saw the team repair a Pilatus PC-6 in the Indonesian jungle. In Switzerland, the team supports RUAG on the Artemis project for the US Navy, which updates 22 Northrop F-5 Tiger jets for training use. It also replaced an upper cockpit longeron on an F-5.

Kaelin also builds its own projects. The Eye in the Sky kit for AS350 and H125 helicopters enlarges the cabin floor window by 350 percent. The company rebuilt the Junkers F 13, a 1919 aircraft, and revived the Junkers A50 Junior and A60 as light aircraft. A new aircraft, the B-100C, made its first flight on 26 June 2026.

Services

• Design and development
• Single piece production
• Structural assembly
• Structural repairs
• Aircraft restoration
• 3D scanning and reverse engineering
• CNC milling
• Aviation welding
• Surface treatment
• Prototype building