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.

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.

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

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.

• 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.

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

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

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.

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

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

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).

• 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

• 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

• 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.

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.

• 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

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.

• 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

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.

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.

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

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.

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.

• 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.