Hills Helicopters, a leader in bespoke helicopter design and manufacturing, required a highly specialised finishing facility for production of the HX50 helicopter. The project demanded spray booth technology and bespoke composite manufacturing environments built to aerospace specification — where environmental control is critical to structural integrity.
Todd Engineering delivered a Poseidon Spray Booth with raised floor for optimised airflow and full downdraught extraction, a dedicated Paint Mixing Room integrated into the booth workflow, and temperature-controlled Composite Rooms maintaining strict environmental conditions to preserve the integrity of composite materials critical to HX50 production. An existing Todd Engineering oven was also relocated to the new facility, ensuring workflow continuity from day one.
Hills Helicopters, a leader in bespoke helicopter design and manufacturing, has revolutionised the aerospace industry with its innovative approach to luxury and performance. To support the production of their renowned HX50 helicopter, Hills Helicopters partnered with Todd Engineering to equip their new purpose-built facility with advanced refinishing and manufacturing solutions.
Hills Helicopters required a tailored setup to enhance their production capabilities while maintaining the highest standards of quality and sustainability. Todd Engineering delivered a comprehensive solution that combined cutting-edge spray booth technology with custom-built composite manufacturing spaces.
Poseidon Spray Booth — Designed with a raised floor for optimised airflow and superior refinishing precision. Equipped with a full downdraught extraction system to ensure a pristine, dust-free environment for flawless finishes. Integrated Eco+ energy-saving modes, reducing energy consumption without compromising performance.
Paint Mixing Room (PMR) — A dedicated space for precise colour matching and preparation, ensuring seamless integration with the spray booth.
Relocated Oven — An existing oven previously purchased from Todd Engineering was relocated to the new facility, ensuring continuity and efficiency.
Temperature-Controlled Composite Rooms — Purpose-built spaces for the precise handling and storage of composite materials. Maintain strict environmental conditions to preserve material integrity, crucial for the lightweight yet durable components of the HX50.
The new facility has significantly enhanced Hills Helicopters' production workflow. The Poseidon spray booth ensures consistent, high-quality finishes, while the composite rooms safeguard the integrity of critical components, enabling Hills to maintain their reputation for excellence in design and performance.
This project exemplifies Todd Engineering's ability to deliver bespoke solutions for specialised industries. By integrating advanced spray booth technology and custom-built composite rooms, Hills Helicopters has positioned itself for continued success in the aerospace sector. Todd Engineering is proud to have supported Hills Helicopters in creating a facility that combines cutting-edge technology with operational excellence.
The installations from Todd Engineering have been instrumental in bringing our new facility to life. The Poseidon spray booth and composite rooms are essential to our operations, enabling us to achieve unmatched precision and quality. Todd Engineering's expertise and attention to detail have exceeded our expectations, helping us align with our vision for innovation and sustainability.
Mark, Production Director, Hills Helicopters
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