Riding the momentum of this success, Omni soon invested in a second ECOSPEED F 1540, integrating both machines into a palletized automated Flexible Manufacturing System (FMS). This smart system enabled continuous, around-the-clock operation, even with Omni’s high-mix, low-volume manufacturing model. The ECOSPEEDs took on highly demanding parts such as wing ribs, machined from aluminum or aluminum- lithium billets weighing up to 5,952 lb. (2,700 kg), with dimensions approaching 157 in. × 59 in. × 6 in. (4,000 mm × 1,500 mm × 152 mm). Some components required up to 95% material removal, a level of material transformation that demands not only brute speed but surgical precision. “While roughing, we can fill a 55-gallon drum with chips in less than a minute,” one Omni technician noted. “Yet the tolerances remain perfectly tight. That’s the ECOSPEED difference.”

At the heart of this performance lies Starrag’s Sprint Z3 parallel kinematic machining head. Using three radially mounted linear drives, the head enables five-axis/ five-sided machining, ±45° spindle articulation, and lightning-fast motion, allowing the spindle to move within a spherical cone at speeds of up to 80° per second. The result? Precision cuts, complex geometries, and faster part completion, even with small batch sizes.

And through it all, the ECOSPEEDs never slowed down. In fact, they became more reliable with age.“ I’m almost embarrassed to admit how many spindle hours we have on our first ECOSPEED without a spindle replacement,” one engineer said. “We run them at 30,000 rpm every day, over multiple shifts, and they just keep humming.”

A new expansion: the third ECOSPEED and beyond

In 2025, Omni Aerospace is once again charting a bold new course. Rearranging their existing production floor to accommodate its third Starrag ECOSPEED F 1540, a clear signal of continued trust and a growing partnership. This third machine will further boost capacity for aluminum parts while allowing the company to reconfigure its existing layout for more efficient workflows. But Omni’s ambitions don’t stop with aluminum. The team is also preparing to expand into hard metal machining, a move that will open the door to an even broader range of aerospace components and deeper vertical integration. “As a fast-growing company, we’re always looking to take the next step. We required a new paradigm for highspeed, medium-to-large, six-axis machining. Starrag’s solution checked every single box.”