What is a disadvantage of poorly prepared holes in aerospace manufacturing?

Poorly prepared holes in aerospace manufacturing can indeed lead to crack formation in the materials. The integrity of a component is critical in aerospace applications, and the manufacturing process must ensure that all holes are of the correct size, shape, and finish. Improperly prepared holes can create stress concentrations, which are points where stress is amplified due to geometric irregularities. This can result in crack initiation and propagation during service, ultimately jeopardizing the safety and performance of the aerospace structure.

While other factors are relevant in manufacturing processes—such as production costs, material requirements, and assembly efficiency—the critical aspect of crack formation highlights the importance of precision in hole preparation. Ensuring that holes are properly prepared mitigates the risk of structural failures, which is essential in maintaining the safety and functionality of aerospace systems.