Flying S Manufacturing’s Metrology-Driven Path to Aerospace Excellence
When Penny and David Shaw founded Flying S Manufacturing in 2001 in rural Crawford County, Illinois, they weren’t following a business playbook or a catchy slogan. They were simply building something they believed in, rooted in values, quality, and a sense of community. Twenty-four years later, that belief has proven itself. “If you build it right, they will come” has become less of a saying and more of a reflection of how Flying S organically attracted customers, employees, and community support by consistently doing things the right way.
Flying S is a woman-owned aerospace design consultancy that has evolved into a community-driven aerospace engineering and production powerhouse, known for its commitment to high-quality output, a deep-rooted culture, and cutting-edge technology. Central to that evolution has been the relentless pursuit of quality and process control, supported by a key relationship with Verisurf- a metrology software company that has become integral to Flying S’s inspection, prototyping, and reverse engineering workflow.
From Humble Beginnings to Expansive Growth
Penny and David started with a passion for aerospace, a vision, and a modest barn facility. Fast-forward to today, and the company now operates out of a 175,000-square-foot state-of-the-art facility, across the road from their cattle ranch where they raise organic, grass-fed beef. Now, in its sixth major facility expansion, which is more than just added space; it’s a symbol of Flying S’s steady and calculated growth.
Employee growth has mirrored the company’s trajectory. In 2018, the company had around 70 employees. Today, that number has doubled to 140, including a 15-person inspection team. This team plays a critical role in ensuring that Flying S meets its 100% aerospace-focused mission—serving aviation, defense, and space industries with components that meet exacting standards.
Equipment, Capability, and Repeatable Control
With growth comes the need for more equipment and, more importantly, repeatable process control. Flying S has transformed from a boutique consultancy into a vertically integrated aerospace manufacturer. The machine shop, once a support function for composite work, now stands strong on its own, handling complex, high-tolerance components with increasing capability.
Since 2019, Flying S has nearly doubled its equipment base from 25 to 47 machines, while maintaining lean operations, thanks to automation and smart staffing.
Machine utilization is optimized through ‘lights-out’ operation, palletized systems, and high-mix production strategies. Additive manufacturing also plays a growing role, particularly in fixture development, which begins in Verisurf, is 3D printed for validation, and then machined.
The shop’s evolution has enabled Flying S to transition into larger, more complex parts and higher-level production, solidifying its role as a go-to source for mission-critical aerospace manufacturing.
Quality – The Heart of Flying S
Despite all the investments in machines and square footage, Flying S’s growth would not be possible without an equally robust investment in quality verification. Aerospace demands perfection, and Flying S meets that demand through discipline, technology, and people.
The 6,400-square-foot inspection department is equipped with:
- Verisurf software
- 4 CMMs
- 5 portable arms
- Laser scanning systems
- Three Zeiss ScanBox systems (ranging from 0.5 to 3 meters)
Initially, the company started with just two metrology devices and three Verisurf seats. Today, they operate with 17 seats of Verisurf, integrating the platform across engineering, inspection, prototyping, and fixture design.
Verisurf is more than just software; it’s an ecosystem that supports Flying S’s commitment to closed-loop manufacturing: design, build, and verify- all on a single software platform.
Verisurf – The Backbone of Quality and Innovation
Verisurf’s role at Flying S goes far beyond simple measurement. It serves as a common platform that allows inspection, engineering, and production to speak the same language. Its universal compatibility with all hardware and any CAD file makes it ideal for Flying S’s diverse workflow. By closing the design, build, verify loop, Verisurf takes in all measurement data, regardless of device type, analyses the data against the nominal CAD model, or drawings, provides reporting, and can pass the data set downstream to other applications, such Statical Process Control (SPC), Product Lifecycle Management (PLM), and more.
“We’ve been using Verisurf for a long time,” says a senior quality leader, Adam Wesley. “The software is very good and dependable. But more importantly, Verisurf delivers solutions, not just software.”
Unlike some hardware vendors who offer limited integration support, Verisurf backs Flying S with extensive training, consulting, and on-site collaboration. That relationship has proven critical as the company scaled its operations, needing a robust and intuitive system that could be used across the entire manufacturing enterprise, adapt to new machines, and quickly close quality gaps.
Verisurf is also used to create and append CAD models, making it a core tool for reverse engineering, prototyping, and tooling, in addition to part validation. For example, Flying S recently completed an MRO (Maintenance, Repair, and Overhaul) job on the landing gear of a vintage Spartan Executive aircraft, built in the 1930s. A critical component of the gear was found to be damaged and required replacement. Using the original artifact, an intelligent CAD model was engineered and used to machine and verify a replacement part.
A Culture of Ownership, Character, and Community
Flying S’s success can’t be measured by output alone. It’s also defined by a culture that places people first. The company operates under an Employee Stock Ownership Plan (ESOP), giving every employee a vested interest in the company’s success. That ownership translates to a deep commitment to the company’s mission of excellence.
“I have worked for large aerospace companies in major markets and just accepted that location was the price I had to pay to hold a senior engineering position in the industry. I still can’t believe I wake up every day in beautiful Crawford County and go to work at one of the leading aerospace engineering and manufacturing companies in the country,” said Adam Krupp, senior aerospace engineer. “The life work balance and sense of community both on the job and off are exceptional.”
“We’ve pulled together a group that’s all-in,” says Wesley Jones, quality supervisor. “We hand-pick employees who are makers—people with good character and mechanical instincts. Often, those who work in farming or ranching fit right in – they know how to build and fix things, which is a testament to our company’s ranching roots right across the road.”
Internships function as proving grounds—informal apprenticeships to identify and train talent. Flying S also recruits through job fairs and invests in community outreach, from preparing meals for local seniors to storm cleanup efforts. A chef-run cafeteria serves both employees and the community, with proceeds funding local charitable causes.
“Culture is big here,” says Jones. “Everyone knows someone in the community, and that creates accountability and pride.”
Training, Talent, and the Challenges of Scaling
With growth comes growing pains. Recruiting high-quality talent in a rural location was once a challenge, but Flying S’s reputation now draws people in.
“Within the last year, our public recognition has exploded,” Jones says. “Now, people come to us.”
Still, training and leadership development remain top priorities. Verisurf’s user-friendly interface (especially its integration with Mastercam) helps streamline onboarding, making it easier to bring new inspectors and engineers up to speed quickly.
As Flying S moves into higher-level assemblies and more complex geometries, its reliance on consistent processes and flexible software will only increase. Every new machine, every new employee, and every new customer raises the stakes, demanding systems that support scale without compromising quality.
Looking Ahead
Flying S Manufacturing has grown steadily and deliberately over the last 24 years, expanding its people, equipment, and capabilities while never losing sight of what matters: quality, community, and doing things the right way.
Its success is powered by repeatable process control, fueled by smart investments in people and technology, and enabled by a deeply strategic relationship with Verisurf—a partnership built not on transactions but on trust, adaptability, and shared goals.
As Flying S continues to grow in size and impact, one thing is certain: this is a company that isn’t just building parts—they’re building a legacy.
For more information: www.verisurf.com
