Thermoplastic Composites - Aerospace and other Sectors

ÉireComposites is involved in serial production, prototyping and R&D in thermoplastic composite components (typically CF/PPS, PEKK and PEEK) for the aerospace industry, using both press-moulding and autoclave facilities. Components are inspected using C-Scan and other NDT techniques, trimmed and are then finished in our accredited painting facility.

The company is also involved in production of thermoplastic composite components for other sectors such as wind, marine and automotive sectors. The materials of choice in these areas are glass-fibre reinforced polypropylene and glass-fibre reinforced engineering thermoplastics such as PBT and PA-6.

See section on Thermoplastics Composites Explained for more information on thermoplastic composites.

Equipment and staff used in general aerospace manufacturing includes:

• Refrigerated store for prepregs and resins - calibrated to aerospace standards
• Clean room - calibrated to 100K
• Paint booth - calibrated to aerospace standards
• Grit blasting unit - calibrated to aerospace standards
• Non-Destructive Testing Facility:
• 1 m2 Krautkramer Ultrasonic C-scan
• A-scan
• Tap testing
• Level II & level I
• Consultant level III

Autoclave Manfacturing

Autoclave manufacture of thermoplastic composite components for aerospace and automotive/F1 is carried out in the following equipment:

• 1.5 metre diameter x 3.0 metres long autoclave, 10 bar pressure, 400ºC. manufactured by LBBC in Britain, 2003, electrically-heated, pressurised by compressed air or nitrogen.
• 0.6 metre diameter x 1.2 metre experimental autoclave, 20 bar pressure, 450 ºC, electrically-heated, pressurised by nitrogen - mainly used for prototyping.

Both autoclaves are regularly thermally-surveyed.

Press Forming

Press-forming of thermoplastic composite components for aerospace and automotive/F1 is carried out in the following equipment:

• 100 tonne double-daylight press, platen sizes 1.5 metre x 0.5 metre, 450ºC
• Infrared rapid heating system for press-forming of thermoplastic composites

Vacuum Consolidation

ÉireComposites carries out serial production of glass fibre-reinforced polypropylene components for using vacuum consolidation in ovens or on our patented MECH Tool system. GF/PP is an extremely tough, lightweight composite and provides for lighter weight and superior durability when compared with thermoset composites such as glass/polyester etc. These composites have particular applications in sectors such as wind energy, marine and automotive/F1 for lightweight replacement of metals or thermoset composites such as glass-fibre polyester.

See section on Thermoplastics Composites Explained for more information on thermoplastic composites.

Thermoplastic composites