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Aviation & Aerospace

Aviation & Aerospace
Honeycomb cores were first used on aircraft in the 1940s to reduce weight and increase payload and flight distance. They were incorporated into the aircraft design to replace the heavier conventional sheet and stringer or beam support approach, and their incorporation into sandwich panels has been a basic structural concept in the aerospace industry since the 1950s. In 2000, virtually every commercial and military aircraft depends on the integrity and reliability offered by honeycomb cores. There are numerous substrate materials with the honeycomb category. Honeycomb cores can have a density as small as 16 kg/m3. Every multi-engine airplane flying today in the world has some honeycomb core parts.

The main use of honeycomb is in structural applications. This is because honeycomb sandwich panels are extremely efficient in stiffness-to-weight and strength-to-weight situations. Whenever light weight is a premium, honeycomb sandwich construction is very difficult to beat.

Reduction of mass has always presented a challenge to the Design Engineer. A typical example of this is in the Aircraft Industry, where every extra kilogram of structural mass costs the Airline operator a huge amount each year.
  • Civil Aircraft
    Civil aircraft continue to consume greater levels of composites, benefiting from their strength and stiffness, tolerance of temperature extremes, high resistance to corrosion and fatigue and the weight saving opportunities.
  • Defense Aircraft
    In their quest for superior performance, Defense aircraft designers were the first to experiment with new materials and to demonstrate the effectiveness of composites. Today, the requirement for optimized aircraft designs, enabling pilots to perform advanced acrobatic manoeuvres, has led to a greater use of composites than ever.
  • Helicopters
    Both Civil and Defense helicopters consume large quantities of honeycomb components. Many parts are manufactured from honeycomb, including the side walls, floor panels and main rotor components.
  • Space
    Space launching satellites into space creates the ultimate performance challenge for composite materials. In addition to the crucial weight savings, the materials also have to withstand extreme temperature fluctuations. The performance requirements can be accommodated by the wide range of composite materials available.

Benefits of using Honeycomb Panels:
  • High stiffness and strength
    Honeycomb Panels are Durable, providing excellent fatigue, impact and environmental resistance. High stiffness from structural materials reduces (even eliminates) supporting framework, increases passenger room, carries fittings readily.
  • Design flexibility
    Design may be tailored to suit exact engineering requirements. Cut and fold technique may be used to save time.
  • Weight savings
    Nomex® and Aluminum Honeycomb are extremely lightweight cores with high temperature resistance brings associated benefits of high-speed and low fuel consumption, resulting increased passenger satisfaction and improved airline profits.
  • Corrosion Resistance
    High resistance to fatigue as composites are rust and rot resistant
  • Cost
    Lightweight, modular interiors are easy to handle & install and offers rapid fitting, resulting man hour savings. The noncorrosive materials reduce maintenance costs.
  • Safety
    Enhanced safety features include the incorporation of fire resistant materials and the elimination of sharp, jagged edges in a crash situation.
Product & Services:
  • Catering and Galley Modules
  • Partitions and Doors
  • Passenger and Cargo Flooring
  • Ceiling Panels
  • Toilet Modules
  • Engine cowling
  • Trailing and Leading Edges
  • Ailerons and Flaps
  • Fuselage components
  • Access Panels
  • Helicopter rotor blades

Manufacturing & Assembly:
Our facility is dedicated to material processing, manufacturing and assembly of a wide range of lightweight panels and structures.

The modern facilities include:
  • Vacuum Bagging Presses
  • Cold & Hot Press
  • Honeycomb Expander
  • Metal Pre-Treatment
  • Adhesive Applicators
  • Composite Machine Shop
  • CNC Router
  • Cleanroom

Final assembly, NABL accredited testing facilities complement production to provide a complete solution.

Design & Validation:
We have extensive experience in design and validation. We can provide:
  • Initial Concept Designs
  • Material Development
  • Mock-ups
  • Testing
  • Validation
  • Prototypes
  • Detailed Manufacturing Drawings
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