Defense
Composites for any mission
A sustainable defense program requires cost-saving solutions that enhance your equipment and its lifespan. We make high-performance assemblies and parts for aircraft, vehicles and surveillance applications.
Discover how our composites play essential roles in America’s ongoing conflict with enemies of freedom.
Learn MoreUAV Fan Duct
Honeywell
We partnered with Honeywell to build ducted fan parts for unmanned micro aerial vehicles (MAV) used by both military and civil authorities. These components are essential to the operation of the unit.
Project Highlights
- Cost savings with out-of-autoclave manufacturing
- One-shot lost core resin transfer molding (LCRTM)
- Over 600 total fan ducts manufactured
- Dimensions: 14.5 inches by 8.5 inches
Measuring 14.5 inches long by 8.5 inches high, the hollow-cavity part featured an integrated motor-mount fan duct and an internal fuel chamber made out of carbon fiber. Other special features included multiple encapsulated mandrels that were created in one shot by LCRTM. We also utilized conventional matched-die RTM and out-of-autoclave processing to lower the client’s costs. Each unit was meticulously trimmed by our CNC machine. More than 600 fan ducts were delivered so that the T-Hawk™ fleet can perform target acquisition and reconnaissance missions.
Landing Gear Strut
General Atomics Aeronautical Systems
The Predator® MQ-9 Reaper plays a quintessential role in America’s ongoing conflict against enemies overseas and at home. General Atomics asked us to improve the performance and takt time of the Reaper’s landing gear strut.
Project Highlights
- Cost savings with out-of-autoclave manufacturing
- One-shot lost core resin transfer molding (LCRTM)
- Dimensions: 73 inches by 8 inches
- Volume: 500+ units
CNC machining produced a complex hollow-cavity part measuring 73 inches long by 8 inches wide. Two crucial processes saved our client time and money: First, we incorporated hollow-core, negative draft geometry made with a single monolithic mandrel using one-shot LCRTM. We then employed conventional matched-die RTM and out-of-autoclave curing to lower the client’s overall costs. Not only did our composite strut improve the Reaper’s performance, but the manufacturing process ensured a quick turnaround.
Flaps and Ailerons
AAI Corporation
The Shadow® 200 unmanned aerial vehicle (UAV) was deployed by the U.S. Army and Marine Corps to provide brigade commanders with real-time battlefield footage. We were approached by the AAI Corporation to manufacture wing flaps and ailerons for controlling the Shadow® 200 in flight.
Project Highlights
- One-shot matched-die resin transfer molding (RTM)
- Lightweight carbon fiber and foam core
- Dimensions: 59 inches by 7.5 inches
- Volume: 600 sets (2,400 pieces total)
The wing flaps measured 59 inches by 7.5 inches, and the ailerons were 32 inches by 5.5 inches. Our CNC router quickly cut each part from carbon fiber material. We then built a foam core in one shot using matched-die RTM and out-of-autoclave processing, which allowed for seamless integration with the outer structure. We completed the job by applying a prime and top-coat finish featuring gray paint and stenciled black lettering. 600 ship sets were produced, each one containing two flaps and two ailerons that enhanced the aerial flexibility of the Shadow® 200.
Tail Spar
General Atomics Aeronautical Systems
General Atomics approached us to engineer a 14-foot carbon fiber ruddervator tail spar for a developmental unmanned aerial vehicle (UAV) application. Using our proprietary lost core resin transfer molding (LCRTM), we created the part in one shot as a single, unified piece with a hollow cavity. Out-of-autoclave curing and conventional matched-die resin transfer molding (RTM) saved the customer time and money.
