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Composite Design & Manufacturing services

Are you in need of composite products but don’t have the capabilities, expertise or machines to take care of the manufacturing process in-house? In other words: are you looking for composites design engineering and manufacturing services for (part of) your production process? Airborne has everything it takes to make high-end composite products. We can support your product design as well as provide built-to-print manufacturing.

Not every composites product is ready or viable for high-volume production. Sometimes all a customer needs is support in just part of their current manufacturing process. From lay-up to prepreg cutting, curing to milling and measuring to repair: you can outsource your task to one of Airborne’s sites.

In projects where we supply automated manufacturing systems, Airborne can take the initial manufacturing on-board, industrialise, ramp it up and then hand it back over once production is robust and in full swing. This gives much more flexibility in make-or-buy decisions and reduces the risk for customers to adopt automation.

Manufacturing services

Advanced 3D design

For 25+ years we have been designing composites products. We know how to create the right product that fulfils the requirements and is strong, stiff and efficient enough to manufacture. We use advanced 3D design and finite element analysis tools and understand the materials to create the proper input data. Over the years we have created many different, qualified product designs in different markets, both in thermoset and thermoplastic composite materials. When it comes to ‘design-for-manufacture’ that is where we add real value to your product.

Automated Cutting

Without the right tools, the cutting of composites can pose a challenge. Our Lectra cutter machine can help you save time and money. The Automated Cutting Table can cut all kinds of materials, from plastics to fabrics and adhesive films to prepreg.

If you provide Airborne your drawing files, we can ensure optimal material usage efficiency.

Technical specifications

  • Roll width: max 1.83 m
  • Material types: Plastics, fabrics, adhesive films, prepregs etc.
  • Cutting accuracy: ±0.4mm for minimum length of 2000mm and width of 1500mm
  • Vacuum: Variable vacuum pressure for cutting different range of materials
  • Marking of Cut Pieces: Each separate ply is automatically marked with its identification

Cutting file preparation

  • Cutting file extension: .PLX
  • Optimized cutting file programming: Provide us your drawing files, so we can ensure optimal material usage efficiency

Autoclave and Oven

To meet composites performance requirements,  such as high stiffness, strength and integrity, it is important the structures get the proper cure. Composites are conventionally cured in autoclaves or curing ovens. At the Airborne site we have an Autoclave and an Oven machine.

Autoclave - Technical specifications

  • Dimensions: 2,60 x 13 m
  • Vacuum: 4-100 KPa absolute
  • Pressure: 100 – 800 KPa
  • Temperature: 220 °C
  • Thermocouple connections: 36
  • Certification furnace class: AMS2750E – Furnace Class 2
  • Custom cycle programming: heat up/cooldown rates, dwell times, step cures and more.

Autoclave - Cure equipment, Flat surface

  • Surface types: Steel, CFRP (polished)
  • Flatness Local: 0.1 mm / 100 mm2
  • Flatness Global: 0.8 mm / 7 m2

Oven machine - Technical specifications

  • Dimensions: 5,15 x 1,7 x 1,9 meter (LxBxH)
  • Vacuum: 10-100 KPa absolute
  • Temperature: 220 °C

Coordinate Measurement Machine & Absolute Laser-tracker

Airborne has two measurement devices for both small and large products. Our fixed bridge Coordinate Measurement Machine (CMM) can carry out 3D measurement of small products with high accuracy. Our mobile Laser-tracker measurement device can be used to measure relatively larger 3D objects and surfaces.

CMM - Technical specifications

Products are measured based on the model or drawing requirements. Results will be reported in a clear report, stating the actual measured values compared to the drawing values. The machine is positioned in a climate controlled room for maintaining constant environmental conditions.

  • Machine type: Hexagon M1S349EC
  • Sensor type: Touch probe (discrete point)
  • Workbench dimensions: 1200 x 3000 x 1000mm (LxBxH)
  • Accuracy: 0.001 mm

Absolute Laser-tracker - Technical specifications

Accuracy

  • Max. Permissible Error 0.03 mm | Range 2 m
  • Max. Permissible Error 0.06 mm | Range 5 m
  • Max. Permissible Error 0.11 mm | Range 10 m

Two milling machines

CNC milling will accurately finish your composites parts in the required shape with the right features, such as precision holes for the required interfaces. At the Airborne site we have two machine types available, for the precise contouring of flat products (3-axis) and the more flexible shaping of products from all sides (5-axis).

Technical specifications

  • Machinable materials: Composites, aluminium, wood, plastics, foams and more.
  • Milling file preparation: We also offer programming services if digital product files are provided to us.
  • Possible file extensions: STP, IGS, SLDPRT
  • Special remarks:
    • No fluid-cooling system included
    • Machine bench with vacuum fixation system implemented
    • Tool storage mechanism including 12 (3-axis) & 8 (5-axis) slots

CNC milling machine 3-axis details

  • Machine type: EiMa OMEGA 11843
  • Operational dimensions: 5200 x 2600 x 300 mm
  • Accuracy (at 20 °C) X-axis: 45 μm at 5000 mm travel
  • Accuracy (at 20 °C) Y-axis: 28 μm at 2600 mm travel
  • Accuracy (at 20 °C) Z-axis: 16.5 μm at 300 mm travel
  • Spindle speed: 24,000 rpm max.
  • Machine is situated in a condition controlled room

CNC milling machine 5-axis details

  • Machine type: CMS Poseidon
  • Operational dimensions: 7500 x 3800 x 2000 mm
  • Accuracy (at 20 °C) X-axis: 0,31 mm at 7500 mm travel
  • Accuracy (at 20 °C) Y-axis: 0,2 mm at 3800 mm travel
  • Accuracy (at 20 °C) Z-axis: 0,35 mm at 1900 mm travel
  • Spindle speed: 12,000 rpm max.

Painting cabin

Our temperature controlled painting cabin can be utilized to safely apply primer and paint to products. Our personnel is certified for and experienced with painting high-class aerospace products.

The paint booth can also be used as post-cure facility for further strengthen larger composite structures.

Technical specifications

  • Application quality and thickness of paint layers are verified with calibrated measurement devices
  • Dimensions: 4 x 8 x 3,5 m
  • Cabin temperature: 80 °C max.
  • Training: Aerospace Certified

Manual and automated layup

Airborne has the skills and experience to produce high-end carbon fibre (aero)space products. We provide both manual lay-up as automated laminating services.

Experience the benefits of a fully automated and digitally implemented production process with our Automated Tape Laying (ATL) service.

Automated Tape Laying - Technical specifications

  • Capable of producing CFRP laminates from roll to net sized products
  • Algorithm based software transforms needs to machine controls that steer the robot in creating the desired product
  • In addition to the laminating function, the ATL is able to cut the laminate into segments and pick & place them onto a separate table in specific orientations and configurations
  • Work field: 2100 x 8000 mm
  • Roll width: 150 mm
  • Material: Carbon fibre prepreg

Manual lay-up details

Our employees are trained to work with different types of materials and different levels of precision. Hand laminating can be supported by a laser projection system to ensure correct placement of plies in a laminate.

Infusion processes

Airborne has developed extensive experience in ‘infusion’ processes including RTM, VARTM, and single sided mould infusions under vacuum bag. Components can range from e.g 300mm x 300mm to an upper scale example within RAMSSES (EU2020 project) of a 6m x 3m infusion with >200mm laminate thickness.

Airborne can provide support on component design to make suitable for infusion, tooling design, process development and production supply of components.

Specifications

Equipment available to support infusion processing includes:

  • 12m x 3m x 3m oven
  • 3 Ciject injection machines
  • Electrical heating and control systems for heated moulds
  • Ply cutters
  • Automation equipment to produce preforms

Composite repair solutions

Besides creating composites, Airborne has the knowledge and experience to perform repairs on composite parts as well. Airborne offers a wide range of composite repair solutions that can be applied to products of both flat, irregular, and complex curved surfaces. Since every damage case is unique, Airborne will assess the situation to advise or determine the most suitable approach for recovery of the product.

How it works

Send us your request and we will come up with a suitable offer. In case we see more options, we will contact you to discuss which solution fits best with your needs. For questions or quotations, please contact:

Burak Cakir
Business Development Manager Aerospace

Tel +31 (0)6 1376 8909
b.cakir@airborne.com

Two sites for composites manufacturing

At Airborne, we have two sites where we can provide composites manufacturing services: at Ypenburg in The Hague, The Netherlands and at Membury Airfield in Lambourn, UK.

Airborne Aerospace, The Hague, The Netherlands

Certified Aerospace design and manufacturing site

The site in the Netherlands is a fully equipped and aerospace qualified manufacturing site (AS9100), with cleanroom, oven and autoclave capacity, 2D and 3D milling stations and certified quality inspection systems. Also, it has our automated manufacturing systems available for efficient and high rate manufacturing.

Airborne UK, Lambourn, United Kingdom

Design and manufacturing site

Airborne UK can provide an end-to-end service for composite structures providing design services, tooling production, prototypes and manufacturing.

Qualified personnel:

Production personnel and machine operators are trained and qualified for the manufacturing and inspection of composite parts for aerospace and other high-end lightweight applications.

The site specialises in:

  • Pragmatic and cost effective tooling and low volume production for clients early in their product lifecycle
  • Supporting the transition from low volume to higher volume with judicious anticipation & application of automation for clients who’s products are maturing.
  • Resin infusion and RTM production with particular know-how in thick structure, or challenging applications.
  • Manufacturing components from fibre reinforced thermoplastic composite materials
  • Manufacturing as a Service using our Automated systems or manual production.

More products & services

Digital Solutions

Digital design and engineering

Want to use composites without first becoming an expert? Our smart digital and software solutions make composites and automation available to anyone.

Learn more

Automated Systems

Want to get started with automation? Airborne offers various automated solutions and techniques to help you move forward.

Learn more

Industrialisation Partner

In need of advice? From first ideas to implementation, with our 25 years of composites know-how we are here to help answer any questions.

Learn more

Get inspired

Satellites and substrate panel production

Airborne UK producing Turtle Shells

Supporting student teams

At Airborne we believe in a new world where boundaries are continiously explored. We believe in winners who challenge these boundaries and push them. Therefore we support and sponsor several student teams who aim for the sky and want to make their dreams real.

Hyperloop

The TU Delft Hyperloop team is trying to build the fastest Hyperloop. Several of the main components of the Hyperloop vehicle are manufactured with Airborne’s automation technology. We are a proud sponsor of the Hyperloop team and look forward to see what innovative solutions they come up with.

Silverwing

The Silverwing Aeronautics students from TU Delft are working on their latest design of a near-VTOL personal flying aircraft, with some help at the Airborne facilities. We are thrilled to be sponsor of their quest to win the Go Fly competition of Boeing, where the use of composites play an important role to make the aircraft light and strong.

AerGo

AerGo is a TU Delft student team with great ambitions when it comes to building the world’s lightest electrically powered personal aircraft. We are proud sponsor of their ambitions.

Human Power Dream Team 

The Human Power Team is a student team consisting of students from the TU Delft and the VU Amsterdam. Its objective: to break the world speed record for human powered vehicles. They do this by building an aerodynamic vehicle, called the VeloX. Airborne helps the team to get the materials they need to produce and we provide an oven for post-curing the bike.

Forze

Forze Hydrogen Electric Racing is a TU Delft student team promoting hydrogen technology by designing, building and controlling a unique race car. Airborne provides space and technical support in the production of all composite components and supervises the production.

DARE

DARE (Delft Aerospace Rocket Engineering) is one of the most advanced student rocketry teams in the world, based at TU Delft. Since their founding in 2001, they have accumulated over 19 years of experience in high-powered rocketry. Airborne provides the DARE team hands-on composites experience to reach space with a fully student-built rocket.

Contact

Burak Cakir
Business Development Manager Aerospace

Tel +31 (0)6 1376 8909
b.cakir@airborne.com
Contact

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  • Home
  • Products & services
    • Industrialisation Partner
    • Automated Systems
      • Automated Preforming
      • Automated Kitting
      • Automated Laminating
      • Automated Honeycomb Potting
      • Automated Edge Sealing
      • System Integration
    • Digital Solutions
    • Design & Manufacturing
  • Industries
    • Aeronautics
    • Automotive
    • Space
    • Renewables
    • Marine
  • Vision
  • Downloads
    • Brochures & Specifications
    • White papers & Trend reports
    • Technical papers & Presentations
    • Webinars
  • About us
  • News
  • Blogs
  • Careers
  • Contact
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