Off-the-shelf engineering is not an option in high-performance environments. Take aerospace. Whether engineers are designing advanced satellite housing, a next-gen drone, or a specialized component capable of handling high speeds and pressures, they are not looking at traditional parts to build their assemblies. They need the best and most advanced parts they can find.
Aerospace composites give them an edge. More importantly, custom composite assemblies can make the difference between a high-performance design and one that is merely adequate. Aerodine excels at delivering precisely what engineers require.
We specialize in the science of advanced composites. We take a simple principle – combining two or more materials to create a new material with superior properties – and apply it in the aerospace industry to create parts and assemblies that are both lightweight and incredibly strong.
A composite is any material manufactured by combining two or more materials with desired properties. For example, engineered wood flooring and laminate countertops are both composites. Advanced composites go one step further by combining materials capable of withstanding significant punishment. They are the core of the high-performance assemblies that aerospace manufacturers rely on.
Typically, an advanced composite comprises two key components:
Combining fiber and resin alone does not always address a manufacturer’s needs. So engineers also work on different fiber alignments along with layup and curing options. As an example, layering fibers in a specific direction and then ‘baking’ them into the finished material through high heat and pressure curing results in a material that is stronger than steel at a fraction of the weight.
The weight savings that advanced composites afford are not to be taken lightly. Reducing weight is the holy grail of aerospace engineering. Every ounce saved equates to greater fuel efficiency, greater payload capacity, and higher air speed.
Building composite assemblies for aerospace applications is tricky business. Engineers cannot afford for their assemblies to fail mid-flight, for obvious reasons. Therefore, the journey from initial design to full flight is a slow and deliberate one. We can break it down into four steps:
Every composite assembly begins as a concept – an idea in someone’s mind. A client will come to us with some sort of need, like a camera housing for a high-altitude balloon. We take that idea and begin investigating feasibility.
We look at the stresses the housing is likely to undergo, and the time engineers expect the balloon to be in the air. We even consider the camera function. In the end, we want to know if we can produce a part that will meet the client’s needs.
In our industry, tooling is the process of designing and creating the mold necessary to build a part. But we need to do it backwards. In other words, our tool needs to offer the exact shape of the final part. Even more important is the fact that a finished tool must be incredibly precise. We cannot even allow a microscopic deviation that could possibly effect performance, integrity, or safety.
With a tool ready to go, we can begin the layup process. This process involves laying either dry fiber panels or prepregs into the mold. If using dry panels, each layer must be manually saturated with resin. Prepregs already come saturated, so the extra step is not required when using them.
Smaller parts can be laid up manually. But larger assemblies can be handled with specialized equipment. Regardless, each layer of fiber must be placed with precision accuracy. No wrinkles or air bubbles can be tolerated.
The final step in building a composite assembly is curing. The most common way to cure composites is with heat and pressure. This is done in an autoclave. Think of an autoclave as an advanced oven. It combines high heat and pressure to bake the fiber panels and resin into a single, solid material.
Following the curing process, parts typically need to be trimmed and finished. In many cases, they are joined with other parts to create a larger and more complete assembly. When multiple parts are made from dissimilar materials, there may be more work involved with the composites.
The whole point of creating customized composite assemblies is to give clients exactly what they need for each and every application. This is especially important in aerospace, where off-the-shelf solutions do not meet critical design demands. With a custom assembly, a manufacturer gets:
From antenna housings to landing gear, advanced composite assemblies make modern aircraft stronger yet lighter. If not for advanced composites, what we now consider normal in commercial and military flight would not be achievable.
The shift toward composite assemblies has changed aerospace forever. As we move forward, customizing those assemblies will be more important than ever. At Aerodine, we are up to the challenge. We are ready to drive the future of aerospace forward.
What makes an advanced composite stronger than steel?
The combination of fiber alignment and resin matrix gives composite materials their incredible strength-to-weight ratios. Composites can handle significantly more tension and stress relative to their weight.
What is a custom composite assembly?
It is a finished, multi-part component made primarily of composites. Think of wing sections with integrated internal ribs and mounting points, all created as a single unit.
Are aerospace composites more expensive?
Yes, building custom composite assemblies is more expensive than using traditional materials. The higher cost is related to raw materials and the labor-intensive nature of composite manufacturing.
Can composite assemblies be repaired?
While repairing composite assemblies is possible, doing so requires a different approach. Proper repairs demand the expertise of composite specialists along with advanced methodologies and techniques.
Are composites just for aircraft skins and cabins?
No. Increasingly, aerospace designers are integrating custom composites into jet engines and other ‘behind the scenes’ applications.
