A range of composite manufacturing processes are suited for prototype and high-volume production. Materials and processes conform to client “build-to-print” specifications or are specially developed to suit new product requirements.
In-house tooling, machining and finishing capabilities assure the highest quality and most reliable execution of manufacturing programs.
Autoclave cured composite laminates, bonded metal structures and bonded assemblies are produced up to 7.5 x 18 feet. Temperature and pressure controls are compatible with aerospace epoxies and other high-performance resin systems.
Along with standard industry cure cycles, custom cure cycles are developed for thick composite laminates, thermal expansion compensation in precision bonded assemblies and control of resin system rheology for optimum laminate quality.
Closed mold manufacturing methods include compression molding, resin transfer molding (RTM), injection molding and vacuum casting. They have been used in production runs exceeding 75,000 units and are capable of producing parts with intricate three-dimensional features on all surfaces.
Material choices extend beyond laminated composites to include alternative reinforcements and matrix systems.
Composite laminate machining and drilling, honeycomb and monolithic core contour machining, metallic and plastic hardware milling, sheet metal trimming and turning is performed in-house for tooling, prototype and production hardware.
Tooling segments, component parts and completed assemblies are 5-axis CNC machined up to 18 feet in length and digitally verified with design model data.
Tooling design and fabrication capabilities support all in-house manufacturing processes. Complete production tool string development capabilities include bond and assembly tools, auxiliary and trim tools, inspection fixtures and test fixtures using both metallic and composite construction.
Quick turnaround tooling methods are available for prototypes and small quantity production runs.
Clean Rooms: Dedicated layup rooms with individual environmental control systems.
Freezer Storage: Prepreg, adhesives and environmentally-sensitive material storage at 0F.
Ovens: Vacuum bag curing, laminate post-curing and thermoforming up to 650F.
Coatings and Finishes: Environmental, wear-resistant, electrical and cosmetic coatings and finishes.
