Department of Defense Applications

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Our close association with Defense OEMs and Prime contractors has provided us the opportunity to utilize our innovative tooling designs and molding experience. Since 1967, we have been providing composite solutions for missile, torpedoes, bunker covers, fuel cells, flight simulators for both F-15 and F-35 programs, ballistic protection covers and multiple impellers/casings for propulsion units.

torpedo and submarine
Composite propulsion parts

Penn St-(Applied Research Laboratory) ARL/US Navy: LWCN-26
Torpedo Propulsion Components

  • Conversion from Machined Aluminum to Graphite/Carbon-Fiber Epoxy Advanced Composites
  • Net-Molded, Minimal Machining Required
  • Selective “Stealth” Core Materials Incorporated into Composition

Significant Gains

  • 10% Reduction in Component Weight
  • 75% Reduction in Component Cost
  • 150% Increase in “JIT” Production Output
F-15 fighter jet flight simulator
F-15 flight simulator

Lockheed Martin, Akron, Ohio
Flight Simulators

  • F-35 Flight Simulator Shells (2007- 2020)
    • CTOL
    • STOVL
    • DMRT
  • F-15E Flight Simulator Shells (49 units)
  • A-6/A-9 Flight Simulator Shells (25 units)
  • Seats, Instrument Panels, Canopy, Glare Shields
F-35 flight simulator and F-35 in-flight
F-35 flight simulator

Significant Gains

  • Significant Cost Reduction from Metal Components
  • Aerospace Approved Materials and Processes
  • Low-Cost Tooling – Multiple Tools Required

NASA – Fuel Cell

  • NASA Funded Development Program
  • Produced 6 Multiple Compartment Fuel Cells
  • 120 Solid Fuel Platforms
  • Epoxy, Spectra, Kevlar, Quartz & ‘S-2’ Glass

Significant Gains

  • Blast/Implosion Resistance Increased Due to Material Selection and Strategic “In-mold” Placement
  • Significant Cost Reduction
  • Low-Cost Model and Tooling
  • Increased Production Output

14ft missile casingMcDonnell Douglas
14′ Missile Protective Container

  • Conversion from Costly Pre-preg Process to Low-Cost Production Process
  • “Out of Oven” Cure Process utilizing Sherwood’s “Out of Oven” Curing Tooling Process
  • Net-Molded, No Machining Required
  • Sherwood Designed and Manufactured Integrated Heated Tooling System

Significant Gains

  • Equivalent Materials, Epoxy/Glass
  • 35% Reduction in Component Cost
  • Increase Production Output from 1 part/36 hours to 1 part/12 hours

Lockheed Martin, Akron, Ohio
Navy Munitions Containers

  • 80,000 Production Parts Produced in a 3 year Run
  • Vinyl Ester/Glass Composite
  • High Dimensional Control

Significant Gains

  • Significant Cost Reduction
  • Increased Production Output
  • Light Weight, Corrosive Resistant, Impact Resistant
  • Low-Cost Tooling for Multiple Tools Required