In the agricultural heartland of Crawford County, Illinois, a national aerospace and defense powerhouse has quietly taken root, defying industry conventions and geographical expectations. Flying S Manufacturing has methodically engineered its ascent from a small, values-driven consultancy into a fully integrated manufacturing leader, proving that a relentless focus on precision, process, and people can build a world-class enterprise far from traditional industrial centers. The company’s story is not one of rapid, venture-fueled scaling, but of deliberate, organic growth where every expansion in capability was anchored by a foundational investment in metrology. This strategic commitment to the science of measurement has been the critical enabler, providing the technological backbone that allowed a rural upstart to compete and win contracts for some of the most demanding mission-critical components in aviation, defense, and space exploration, rewriting the playbook on what is possible for modern American manufacturing.
A Foundation of Values and Deliberate Growth
The narrative of Flying S Manufacturing began in 2001 not with a detailed business plan, but with the unwavering principle of its founders, Penny and David Shaw: “If you build it right, they will come.” This philosophy became the company’s operational compass, guiding a strategy of organic growth built on a reputation for uncompromising quality. Rather than pursuing rapid expansion, the company focused on consistently delivering excellence, which in turn attracted a loyal base of customers and dedicated employees. This deliberate approach is physically embodied by the company’s campus, which has evolved from its humble origins in a barn to a state-of-the-art, 175,000-square-foot facility. In a poignant reflection of its roots, this advanced manufacturing center sits directly across from the founders’ cattle ranch, where they raise organic, grass-fed beef, creating a unique juxtaposition of high technology and pastoral tradition that defines the company’s unique character.
This methodical growth in physical infrastructure has been mirrored by a significant expansion of its workforce, which has doubled from approximately 70 employees in 2018 to 140 today. Central to this growth is the company’s robust, 15-person inspection team, a number that underscores the prioritization of quality assurance in its 100% aerospace-focused mission. Currently undergoing its sixth major expansion, the facility stands as a testament to a business model that prioritizes sustainable development and long-term stability over short-term gains. This steady, calculated trajectory has allowed Flying S to scale its operations without compromising the core values of quality and community that have been the cornerstones of its success from the very beginning. This disciplined expansion has proven to be a formidable competitive advantage, ensuring that every new capability is built upon a solid and verifiable foundation of process control.
The Strategic Pivot to Vertical Integration
A pivotal moment in the company’s evolution was its strategic transition from a boutique design consultancy into a fully integrated manufacturer, capable of handling every stage of production from concept to completion. This was achieved through a calculated expansion of its equipment and in-house capabilities, always guided by a focus on establishing repeatable and verifiable process control. The machine shop, which initially served as a support function for the company’s composite work, has since matured into a formidable, standalone division. It is now equipped to produce complex, high-tolerance components that meet the stringent demands of the aerospace industry, transforming a cost center into a powerful revenue-generating engine and a core element of its vertically integrated strategy. This shift has enabled the company to maintain control over quality and timelines, a crucial factor in the high-stakes world of aerospace manufacturing.
Since 2019, Flying S has nearly doubled its equipment base from 25 to 47 machines, a significant capital investment managed through the disciplined application of lean operational principles. To maximize the efficiency of these assets, the company leverages advanced manufacturing strategies, including automation, ‘lights-out’ unmanned operations for continuous production, and palletized systems that streamline the handling of parts between processes. Furthermore, the firm has strategically embraced additive manufacturing, which now plays an essential role in its workflow, particularly for developing custom fixtures. The process begins with a design conceived in the Verisurf software platform, followed by the creation of a 3D-printed prototype for fit and function validation, before the final, high-precision fixture is machined from metal. This integrated technological approach has empowered Flying S to take on larger, more complex parts and higher-level production contracts, solidifying its reputation as a premier supplier.
Precision as the Cornerstone of Production
The substantial investments made in advanced production machinery would be unsustainable in the aerospace sector without an equally robust commitment to quality verification, where perfection is the minimum acceptable standard. Flying S addresses this imperative through a disciplined combination of technology, processes, and highly skilled personnel. At the core of this quality-centric operation is the 6,400-square-foot inspection department, a space that acts as the final arbiter of precision for every component that leaves the facility. This department is extensively equipped with an array of advanced metrology tools, including four Coordinate Measuring Machines (CMMs), five portable arms for flexible inspection, advanced laser scanning systems for non-contact measurement, and three Zeiss ScanBox automated 3D scanning systems of varying sizes, ensuring that no detail, no matter how small, escapes scrutiny.
Central to this entire quality infrastructure is the Verisurf metrology software, which serves as the universal platform connecting all measurement hardware and design data. The company has dramatically scaled its use of the software, growing from three initial licenses to seventeen, reflecting its indispensable role in the workflow. Verisurf functions as an integrated ecosystem that facilitates the company’s closed-loop manufacturing model: design, build, and verify, all within a single, unified digital environment. Its universal compatibility with any metrology hardware and any CAD file format makes it the common language that allows the inspection, engineering, and production teams to collaborate seamlessly. This system captures all measurement data, analyzes it against the nominal CAD model, and generates comprehensive reports that can be fed into enterprise applications like Statistical Process Control (SPC) and Product Lifecycle Management (PLM) systems, ensuring a complete digital thread from start to finish.
A Culture of Ownership and Community
The remarkable success of Flying S is not solely a product of its technical capabilities but is deeply intertwined with its distinct corporate culture. A defining element of this culture is the company’s structure as an Employee Stock Ownership Plan (ESOP), which grants every employee a vested interest in the company’s performance. This model transcends a typical employer-employee relationship, fostering a powerful sense of ownership, personal responsibility, and a collective commitment to excellence that is palpable throughout the organization. This unique environment has become a significant draw for talent, attracting skilled professionals like senior aerospace engineer Adam Krupp, who found it possible to contribute to a leading national aerospace company while enjoying the work-life balance and supportive atmosphere of rural Crawford County, a combination rarely found in the high-pressure aerospace industry.
This commitment to people extends outward into the broader community, which Flying S views as an essential partner in its success. The company actively seeks to hire “makers”—individuals with strong character, innate mechanical instincts, and a problem-solving mindset. It has found that people with backgrounds in farming or ranching often excel, as their practical, hands-on skills align perfectly with the company’s build-and-fix ethos. Flying S reinforces its community ties through extensive engagement, using internships as a proving ground to identify and nurture local talent, recruiting at regional job fairs, and participating in service projects from preparing meals for senior citizens to assisting in storm cleanup efforts. A chef-run on-site cafeteria not only serves employees but is also open to the public, with all proceeds funding local charitable causes, further cementing a symbiotic relationship of mutual accountability and immense pride among the workforce.
A Legacy Forged in Precision and Principle
Over its 24-year history, Flying S Manufacturing demonstrated a powerful model of steady, deliberate, and sustainable growth, proving that long-term success could be built on a foundation of repeatable process control. This journey was fueled by intelligent and balanced investments in both its people and its technology. The deeply strategic and collaborative relationship forged with Verisurf was an essential enabler of this evolution, providing an adaptable and robust technological backbone that supported expansion without ever compromising the company’s non-negotiable commitment to quality. As Flying S continued to expand its capabilities and take on ever more complex projects, its core principles of quality, community, and “doing things the right way” remained the guiding force. Ultimately, the company did not just manufacture parts; it built a lasting legacy in the American aerospace industry, one measured component at a time.
