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Net Cured Composites

The majority of today's complex composite structures require post cure machining of features and hole locations. We have developed a unique system for molding in simple and complex features into the product at the time of lay-up. Some products feature over 200 integrated features that require no secondary operations. These net cured composites can feature molded-in holes, slots, hardware, SLS components, antennas, and electronics. The elimination of secondary operations improves manufacturing consistency and reduces unit costs.

Thermally Conductive Encapsulation

Our Oceanside, California facility features work space specifically devoted to the encapsulation of electronic assemblies and electromagnetic coils. This purpose-built equipment meters the injection of potting materials, controls the elevated temperature cure and provides up to twelve channels of data logging capability. Prior programs have required the potting of epoxy and urethane materials with integrated cavities and fluid cooling channels.

Potting techniques include the capability for incorporating integral thermal couples, PCB, and water jackets in the finished assemblies

Composite Live Hinges

Typical Group 1 and Group 2 UAV's utilize live hinges manufactured during the layup of the surrounding wing geometry. Our manufacturing teams have developed several proprietary systems to develop live hinges which are a cut above the rest. Our primary technique utilizes a specially designed tool which starves the prepreg laminate of resin along a .030" wide strip along the length of the control surface. This results in a truly optimal structure which requires no break-in or secondary preparation.

Our other technique for creating live hinges is so revolutionary that we patented it along with our development partner Lockheed Martin.

US Patent # US20150040349 A1

Fine Feature Reproduction

A significant section of todays truly complex composite structures relies on traditional composite geometry mated with high precision features which would commonly be more suited to plastic mold injection operations. We have developed techniques which specifically address theses challenges and are capable of generating high fidelity, void free, precision composite interfaces.

Our unique processing of UAV composite structures utilizes an out of autoclave technique which is capable of delivering selective pressures between 50 and 200 psi.