Summary: Metallic sub-assemblies, comprising hundreds of parts joined by metal fasteners, have been the standard in defense manufacturing for decades. But the need to push the boundaries of our defense capabilities is forcing change. Today, defense contractors need consolidated components made with composite materials.
Tactical and operational vulnerabilities are a normal part of modern military manufacturing. Whether it is a gram of excess weight or additional fasteners in an early-stage design, or even a delay in the supply chain, things can go south in a hurry.
The risks have been exacerbated over the last three decades by having to rely on traditional metallic assemblies composed of dozens or hundreds of machined parts joined with rivets, bolts, welds, and elastomeric seals. Put another way, every part in an assembly introduces a potential tactical or operational vulnerability.
As design has evolved, military applications demand longer ranges, higher payload capacities, stealth capabilities, and even field repairability. Those old assemblies have reached their limit. So forward-looking defense composite manufacturing companies, like Aerodine, are fundamentally changing the architecture with advanced composites and part consolidation.
The composites industry sometimes refers to part consolidation as co-curing, co-bonding, or unitized structural design. It is an engineering process that integrates multi-piece mechanical sub-assemblies into single and continuous composite components.
For purposes of comparison, a traditional aerospace structural housing or control surface might comprise:
Part consolidation replaces these disparate sub-assemblies with a unified structural unit. By combining advanced layout techniques, resin transfer molding, autoclave processing, and precise tooling designs, high-performance defense composites manufacturers are changing the way projects are designed and built.
Today, there is no longer a need to manufacture dozens of distinct metal components, then spend weeks fastening them together. Defense OEMs can produce single composite components that perform all the same structural and environmental functions right out of the mold.
Weight savings is the most immediate impact of replacing metal assemblies with advanced integrated composites. It’s also the one most designers think of first. But there is more to it. For example, applying part consolidation considerably improves system performance.
Carbon fiber-reinforced polymers (CFRPs) and advanced aramid composites offer exceptionally high strength-to-weight and stiffness-to-weight ratios. They are the absolute best choices for replacing metals. Yet the performance gains that come with part consolidation are even more impressive:
One of the things that makes this so fascinating is the fact that composites are made up of two or more materials whose combined properties far outweigh the properties of the individual component materials. Likewise, combining multiple composite components into a single continuous component increases performance properties even more.
From a cost perspective, part consolidation does the unthinkable: it streamlines the manufacturing value chain and lowers production costs. Even though high-performance fibers and specialized resins carry higher initial price tags, they ultimately save money in the long run.
In essence, the higher cost of raw materials is offset by the efficiency gains part consolidation offers. Manufacturers invest less time and labor in assembly without sacrificing finished part quality and integrity.
The benefits of part consolidation extend well beyond manufacturing spaces. They also extend into the field, where readiness depends heavily on how quickly a platform can be serviced. Unfortunately, complex multi-piece assemblies create significant maintenance burdens when field personnel are charged with repairing and returning a unit to duty. Part consolidation directly addresses these burdens.
For instance, composites and part consolidation eliminate the galvanic corrosion to which steel fasteners and aluminum frames are subject. Defense composites do not rely on metallic fasteners and internal metal-to-metal joints. So corrosion is not an issue. The mean time between depot-level maintenance breaks is extended. In addition, part consolidation:
Simplifying maintenance pays off, especially under the pressure of the battlefield. By combining sub-assemblies into single continuous composite units, manufacturers reduce the physical and psychological loads on maintenance crews.
Specialized engineering expertise is necessary to achieve the full benefits of part consolidation in defense composites. Designing a consolidated composite is not a simple matter of duplicating a metal assembly with carbon fiber. In most cases, it requires a fundamental rethinking of structural load paths. Engineers must carefully consider fiber placement, resin chemistry, and even tooling geometry.
With that in mind, partnering with the right defense composite manufacturing companies is key. They bring critical capabilities to the table:
Advanced defense composites are critical to modern warfare. Therefore, manufacturers cannot afford suppliers incapable of meeting the strictest standards. It’s incumbent upon them to partner with defense composite manufacturing companies that understand all the details inside and out.
As defense OEMs continue to push the boundaries, part consolidation will become the chief cornerstone of structural design. We are nearly there already. By partnering with established composite manufacturing specialists, defense contractors can replace older, high-maintenance metal assemblies with modern, streamlined composite structures that perform better, cost less, and keep mission-critical assets operational.
What is part consolidation in simple terms?
In the composites industry, part consolidation is an engineering process that replaces traditional metal sub-assemblies with single, continuous parts made of composite materials.
How does part consolidation impact structural performance?
Eliminating fastener holes and mechanical joints actually improves performance by eliminating stress concentration and fatigue micro-cracks. Moreover, operational loads are distributed more evenly across an entire part, resulting in superior performance.
Does part consolidation reduce manufacturing costs?
Yes. Even though raw materials cost more, part consolidation ultimately saves money by reducing material management complexity, cutting labor, and lowering tooling overhead.
How does part consolidation impact aerodynamic performance and stealth?
In a conventional design, aerodynamics and stealth capabilities are limited by lap joints, seam lines, and exposed fastener heads. Part consolidation improves aerodynamic performance and stealth by eliminating these hindrances.
What processes do manufacturers use to achieve part consolidation?
Single continuous components are manufactured using autoclave processing, resin transfer molding, vacuum-assisted RTM, and bladder and soluble core molding.
