Aerospace Manufacturing: How to Achieve Quality at Rate

DEMAND, DURABILITY, AND SUSTAINABILITY

In the rapidly evolving aerospace manufacturing sector, challenges are plentiful as the industry strives to meet the advanced demands of commercial and defence sectors. These sectors require top-tier aerospace parts that exceed strict standards for performance, durability, and safety.

Additionally, the push towards sustainability intensifies the pressure on manufacturers to minimise their environmental impact by reducing waste and optimising energy use, all while maintaining impeccable quality and precision. Traditional pre-preg processes, while dependable, now struggle with high costs, excessive waste, and lengthy curing times.

WHY INFUSION OVER PRE-PREG?

Traditionally, the aerospace industry has favoured pre-preg materials for their quality. However, these materials come with inherent limitations such as high costs, extensive storage requirements, and labour-intensive processes that escalate operational expenses and restrict scalability.

In contrast, RTM & Direct Infusion presents a favourable alternative, offering enhanced cost efficiency, scalability, and a reduced environmental footprint.

Challenges with Pre-Preg

HIGH COSTS

Pre-preg materials are expensive. Add into the mix specialised storage and often the need for autoclave curing, the costs quickly mount up.

EQUIPMENT REQUIREMENTS

The use of pre-preg materials often necessitates autoclave curing, requiring substantial investment in specialised equipment.

LIMITED SCALABILITY

The intricate handling and laying up processes restrict the scalability of pre-preg, making it less adaptable for meeting increased demands.

EXTENDED CURING TIMES

Typically require prolonged curing times in autoclaves, leading to bottlenecks in production cycles & reduced manufacturing throughput.

LABOUR INTENSITY

Process is labour-intensive, requires a high level of skill from workers, consequently, limiting production speed and increases costs.

STORAGE LIMITATIONS

Materials must be stored in refrigerated conditions to prevent premature curing, imposes additional logistics and storage costs.

LIMITED SHELF LIFE

Potential waste & increased costs due to material chemical fixed shelf life, and potential performance characteristics degradation.

DESIGN INFLEXIBILITY

Pre-preg layup schedules & mould designs are difficult and costly to alter, inhibiting response to new design innovations or changes.

WHY CHOOSE RTM & DIRECT INFUSION?

Dedicated to our mantra ‘there’s always a better way’, we have invested over 2 decades developing Resin Transfer Moulding (RTM) and Direct Infusion. These technologies exemplify innovation in manufacturing, where precision engineering ensures uniform resin distribution—critical for achieving the highest structural integrity, with minimal voids.

Our processes ensure components consistently meet rigorous aerospace standards, thereby maintaining quality at an increased production rate. Our CIJECT® equipment further accelerates the production process without compromising on quality, optimising infusion for faster cycle times and higher throughput.

KEY BENEFITS OF RTM & DIRECT INFUSION WITH CIJECT®

Consistent High Quality

CIJECT® ensures each component consistently meets or exceeds stringent aerospace standards, thanks to its precise control over resin preparation, mixing, injection, distribution and curing processes. This level of control ensures every part follows the same repeatable process, maintaining uniformity in quality and performance.

Cost Efficiency

One of the standout benefits of using CIJECT® equipment is its ability to reduce material waste. The system’s precise infusion techniques ensure that only the necessary amount of resin is used, minimising excess. This not only reduces the cost of materials but also lessens the environmental impact associated with waste disposal.

Additionally, the reduced need for rework and lower scrap rates contribute to overall cost savings, making the manufacturing process more economical and sustainable.

Quality at Rate

CIJECT® allows for acceleration of production timelines without sacrificing quality output. By integrating advanced automation and control systems, the equipment maintains a rapid production pace, enabling manufacturers to meet high demand without delays. Efficiency is achieved through streamlined processes, with each step from resin preparation, to component curing, optimised for speed and precision.

Scalability & Flexibility

CIJECT® equipment is highly adaptable and customisable, capable of handling a wide range of component sizes and complexities. This adaptability allows for manufacture of small intricate parts to large structural components, be it RTM or Infusion. Easily scale your production up or down, based on demand, without the need for significant adjustments in the production setup. New product designs can be accommodated quickly and efficiently.

PUSHING BOUNDARIES

Composite Integration is enabling leading aerospace manufacturers to pioneer advancements in the industry, continuously driving innovation and efficiency.

Our partnership with Safran has been crucial in optimising low-cost infusion technologies, establishing key process parameters that now guide our high- performance infusion methods.

Leveraging Dowty's existing RTM setup, our team of experts transitioned them to two bespoke, fully automated CIJECT3 machines that offered enhanced process control and advanced data systems, significantly boosting production efficiency. The upgrade's success prompted Dowty to expand their fleet with a further four CIJECT3 machines, ensuring scalability with comprehensive training and maintenance support.

Additionally, as associate members of the National Composites Centre, we are actively involved in the Airbus ‘Wing of Tomorrow’ programme, contributing to the development of innovative wing designs for the next generation of fuel-efficient and electric aircraft.

IMPROVED PROCESSES

Leverage our technical expertise through our process consultancy services. We help clients optimise their processes from initial design to final production.

QUALITY & EFFICIENCY

Our dedicated R&D team continuously refine and enhance the capabilities of Direct Infusion technology, to stay at the forefront of composite manufacturing.

ON-GOING GUIDANCE

Equip your team with the necessary skills to maximise the benefits of RTM & Direct Infusion technology, supported by the continuous expert guidance of our team.

RAPID PROTOTYPING

Our prototyping services enable quick turnaround times for test components, crucial for iterative design processes, allowing for fast-paced development.

REDUCED CAPEX & OPEX

Cutting-edge equipment to decrease capital & operational expenditures.

WEIGHT SAVINGS

Achieve designs that enhance fuel efficiency and performance.

COMPONENT DURABILITY

Extend the lifespan of components and reduce ongoing maintenance needs.

ON-SITE SET-UP

Ensure seamless integration of our equipment into your production lines.

THIS IS HOW YOU ACHIEVE QUALITY AT RATE