Processes and Materials

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Prepreg laminating

Prepreg lamination of “solid” and “sandwich-core” aircraft components are performed in environment-controlled rooms within our facility, meeting AS9100 standards and customer specifications. Pre-preg laminates are precisely cut to size using an Eastman CNC cutting table per engineered “cut files” to assure accurate designation of laminate plies.

Various cores, grounding tabs, lightning diverters, and hardware are integrated into the lamination process per customer specifications using precise process standards.

Complete finish trim and painting of all molded components and structures are provided per customer specifications.

Commodities include radomes, SATCom domes, attachment frames, cowlings, fairings, interior components, ducting, etc..

Resin Transfer Molding

RTM uses a liquid thermoset resin to saturate a fiber preform placed in a closed mold. The process is versatile and can fabricate products with embedded objects such as foam cores or other components in addition to the fiber preform. RTM is one of the best methods for mass production of composite parts. It is primarily used to mold components with large surface areas, complex shapes and smooth finishes.

Vacuum Assisted RTM

Vacuum Assisted Resin Transfer Molding (VARTM) uses a partial vacuum on one side of a fiber mat to pull the resin in for complete saturation. VARTM can produce parts with less porosity than regular transfer molding with a proportional increase in casting strength..

Resin Infusion

Resin Infusion is a process we use to produce larger components that do not require the tighter tolerances of the RTM or VARTM processes. Thus requiring a lesser tooling structure and usually lesser material cost. We have produced components as large a 25 feet in length and up to 3 inches thick for components in the Transit, marine and ground radome industries.

Advanced composite materials we work with include aramid, graphite/carbon-fiber epoxy advanced composites, epoxy, fiberglass, Spectra, Kevlar, phenolic, polyester, quartz, ‘S-2’ glass and vinylester.