Aerospace composite manufacturing companies produce all sorts of parts and components designated for air and spacecraft. Given the delicate nature of air and space travel, manufacturers cannot afford to get their composites wrong. That means a lot of time and thought are put into developing composite materials.
Getting from concept stage to full capacity manufacturing can take a long time in aerospace. For example, new aircraft can take years to develop. But even individual components can be in the pipeline for months or years at a time.
Below are five key things aerospace composite manufacturing companies need to think about. They explain why it takes so long to get from concept to design to manufacturing.
Three of the most common composites utilized by aerospace manufacturers are carbon fiber reinforced polymers (CFRPs), glass fiber materials, and aramid fiber composites. All three offer high strength-to-weight ratios compared to alternatives like steel and aluminum.
However, each of the materials also has its own unique characteristics that make it applicable for some applications but not for others. Manufacturers need to carefully consider the materials they will start with.
Next up are the many manufacturing processes engineers can choose from. Autoclave curing is among the most common. It involves curing laid up parts in a special chamber that applies high heat and pressure. If autoclave curing is not appropriate, other options are available:
Like base materials, each manufacturing process has its unique characteristics. Different processes are used to manufacture different parts and components. An engineer’s choice of manufacturing process is critical to final product quality.
The application for a particular part or component must be considered in the early design stage. Parts and components have to perform unique tasks. They must withstand set forces. They are subjected to a variety of performance and environmental variables.
Application plays a role in determining base material and manufacturing process. It also drives design. Manufacturers must give significant attention to application in order to get it right.
An undercurrent running throughout the design and manufacturing stages is quality control. By their nature, composites are deployed for highly technical and complex applications. The more complex, the higher the quality demands.
It is not unusual for composite designs to call for extremely tight tolerances. Likewise, safety specifications demand superior quality that minimizes the risk of catastrophic failure. Aerospace composite manufacturing companies cannot afford to compromise on quality even in the slightest. It is all or nothing where quality control is concerned.
Aerospace composite manufacturers having to meet certification requirements is par for the course. Schemes like AS9100 and NADCAP ensure compliance with industry standards, compliance that is absolutely necessary to obtain certification.
The need for certification is understandable when one considers the implications of building air and spacecraft. Lives are on the line whenever a craft takes to the skies. Putting uncertified parts into an airplane or space vehicle equates to taking unnecessary risks. Manufacturers cannot afford to do so. Their customers cannot afford it either.
Needless to say, aerospace composite manufacturing companies have a lot on their plates. They have to work through a long list of things to get from concept to design to manufacturing. Taking the time and putting in the effort is worth it when you consider what composites have to offer. If not for modern aerospace composites, the way we now travel in air and space would not be possible.
