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COMPOSITE STRUCTURAL DESIGN & DEVELOPMENT

SUPPORTING AIRFRAME, INTERIORS AND ENGINE INTAKE DESIGN, FROM CONCEPT TO CERTIFICATION

STRUCTURAL DESIGN & CERTIFICATION

  • Design development of composite structural components or assemblies, offering advice on composite systems, effective usage, manufacturing options and integration with interfacing new or legacy metallic elements

  • Provide advice on the appropriate analyses, testing & structural optimisation

  • Design definition of geometry, materials, lay- ups, discontinuities, drop-offs & draping

  • Monolithic Carbon, Glass, Kevlar or Boron in numerous epoxy resin systems

  • Honeycomb panels with Nomex or Aluminium cores

  • Structural Damage Assessment, such as Delamination, Water ingress, BVID

  • Electrical continuity inclusion

  • PEEK analysis & assessment

  • Repair Scenarios

  • Impact/Bird strike assessment of composite structures

  • Thermal environment and metallic interaction analysis

MANUFACTURING TECHNIQUES

MANUFACTURING TECHNIQUES

• Development of component manufacturing process
• Autoclave cure temperatures and cycles
• Advice on Mould development & assessment
• Cold cure system assessment
• Automatic Tape layup, manual placement or chop strand injection mould assessment

 

DELEGATED SIGNATORIES

Composite Approval for A350 Fixed Trailing Edge, A400M & Boeing Wide Body Stow Bins

 

 

 

 

 

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EXPERIENCE AT A GLANCE

• A350 Fixed Trailing Edge:
• Led client teams during development of Inner & Outer Structural & Honeycomb Shroud panels
• Certification of the Inner Structural, Shroud & Main Landing Gear Door panels, including all formal documentation including Airbus Stress Dossiers & Structural Repair Manuals
• Development of FE models containing composite structures, including 3D representation of honeycomb regions
• Impact and PRA assessments due to Tyre Burst & Wheel Rim Release
• Type 26 Frigate: Design analysis, sizing and integration for Composite Sandwich Panel Mast superstructure and Shaft Bracket Fairings
• Pall Aerospace: Helicopter Engine Air filters and Intake door Design & Certification analysis, including bird strike
• A350 Rear Fuselage: metallic to composite joint Certification analysis
• Pilatus PC-24: Certification static analysis including engine pylon composite panels
• A320 CPD: conducted investigation into optimised composite re-design of existing metallic belly fairing in order to reduce weight

SOFTWARE & ANALYSIS TECHNIQUES
• Development of Analysis Techniques in conjunction with clients
• Analysis and calculations for all the principal failure modes of composite structures: including joints, strength, buckling and sandwich region wrinkling or core shear
• From Classical Laminate Theory to tools such as Airbus bespoke ISAMI software
• Design Development using CATIA V5 or SolidWorks

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