Composite materials have literally revolutionized aerospace design. Thanks to superior performance and an impressive strength-to-weight ratio, composites allow us to do things that were never before possible. But designing modern aerospace composites isn’t a walk in the park. It requires extensive knowledge, skill, diligence, and a willingness to innovate.
As leaders in aerospace composite design, we know what it takes to create the materials our customers demand. We concentrate on ten key factors to ensure customer satisfaction:
Aerospace composites begin their lives as separate materials, then combined to make something better. Those separate materials are fibers and resins. With each new project comes a critical choice: which fiber and resin matrix to choose.
One application might call for a carbon fiber combined with an epoxy resin. Another might require an aramid fiber with a more complex resin matrix. Needless to say, material selection affects everything from strength and stiffness to thermal resistance.
We pay close attention to a composite material’s strength-to-weight ratio. One of the key reasons for building with composites is to utilize a high ratio to the benefit of the design. A high strength-to-weight ratio offers superior strength that reduces weight, thereby directly affecting everything from fuel efficiency to aircraft performance.
How fibers are oriented and stacked has an impact on certain mechanical properties. By changing orientation, we can modify structural performance along specific axes. Likewise, improper orientation can lead to weaknesses in load-bearing directions.
Aerospace structures must be able to withstand considerable fatigue along with environmental exposure and mid-air impacts. Therefore, aerospace composites need to be durable. They need to be able to stand up to temperature, humidity, repeated cyclic loads, and so forth.
It is important that we also pay attention to how well materials tolerate damage. Composites are more brittle and notch-sensitive than aluminum and steel, despite being stronger. We need to design materials capable of handling minor damage without compromising integrity. The materials should also be fairly easy to repair.
Aerospace applications often call for specific thermal and electrical properties. Specifications might require minimizing electrical conductivity or enhancing heat resistance. Composites must be designed accordingly.
In addition to excellent strength-to-weight ratios, composites also allow designers to dream up very complex structures and shapes. The more complex the shape, the more complex the composites in the design. Added design complexity means more complex engineering and manufacturing.
The manufacturing process chosen for any composite product directly affects the product’s final properties. Therefore, processes need to be chosen in accordance with finished product specifications. We need to choose the right process in order to get the right outcome.
Composites are certainly superior in the properties they bring to the table. But they are also more expensive to produce. We must pay attention to costs in terms of raw materials, tooling, and labor so that customers can still afford to build with composites.
It goes without saying that aerospace structures must meet stringent regulatory requirements in order to pass inspection and gain certification. To ensure this, we need to invest in extensive testing and simulation. We also need to document everything.
Designing aerospace composites for the 21st century is exciting work. But it is also hard work. We wouldn’t have it any other way. The opportunity to contribute to aerospace manufacturing by designing state-of-the-art composite materials is something we take seriously. Hopefully, you see that in our work.
