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UAV FAN DUCT - Carbon Fiber Resin Transfer Molding

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T-Hawk™ Fan Duct
T-Hawk™ Fan Duct
T-Hawk™ Fan Duct Cross-Section
T-Hawk™ Fan Duct Cross-Section
T-Hawk™ MAV with Fan Duct
T-Hawk™ MAV with Fan Duct

Aircraft photo courtesy of Honeywell

When Fiber Dynamics, Inc. was approached to help construct a fan duct for the Honeywell T-Hawk™, we put our skills and advanced technologies quickly to work. Building an essential part of a VTOL unmanned micro aerial vehicle (MAV) that's used by both military and civil authorities for reconnaissance and target acquisition would be a challenge for anyone, but Fiber Dynamics, Inc. was more than ready for it.

By means of matched die resin transfer molding (RTM), and CNC ply cutting, Fiber Dynamics was able to construct a complex hollow-cavity component which included an integrated motor mount fan duct and internal fuel chamber made out of carbon fiber that measured 14.5" long and 8.5" high. Special features included multiple encapsulated mandrels that were built by process of "one shot," lost core resin transfer molding (LCRTM). We also utilized conventional matched-die resin transfer molding (RTM) and the out-of-autoclave process to lower the client’s costs.  Each unit finalized with meticulous CNC trimming, our manufacturing team managed to build over 600 fan ducts for the T-Hawk™.

Fiber Dynamics, Inc. is proud of the results of its work on the T-Hawk™ and of the real-life applications. On April 15, 2011, it was a T-Hawk™ that was used to conduct surveillance of the damaged Fukushima Dai-Ichi nuclear power station following the Tohoku (Japan) earthquake and subsequent tsunami. Hovering high above the battlefields and natural disasters of the 21st century, another quality product from Fiber Dynamics is performing its share of mechanical ingenuity and human creativity. For additional information contact Fiber Dynamics today.

Project Highlights

Product Description
  • Fiber Dynamics, Inc. collaborated with customers to develop a complex, single-piece, hollow-cavity, integrated structure which incorporated an integrated motor mount, fan duct and internal fuel chamber.
Capabilities Applied/Processes
    "One Shot" Lost Core Resin Transfer Molding (LCRTM)
    • Complex Hollow-Cavity Component
    • Out-of-Autoclave Process
    Matched Die Resin Transfer Molding (RTM)
    • Out-of-Autoclave Process
    • CNC Trimming
Overall Carbon Fiber Fan Duct Dimensions
  • Length: 14.5"
  • Height: 8.0"
Material Used
  • Carbon Fiber
  • Multiple Encapsulated Mandrels Using Lost Core Resin Transfer Molding (LCRTM)
Industry for Use
  • UAV (Unmanned Aerial Vehicle)
  • 600+ Units
Delivery Location
  • United States
Standards Met
  • Customer supplied print, 2D CAD Drawing
Product Name
  • UAV Fan Duct

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Fiber Dynamics, Inc. | Composite Solutions Since 1990