Composite Design

Co-Bonded Webs
Traditional wings and flight controls structures require bonded ribs and spars to provide adequate stiffness. Carbon by Design has developed a proprietary technique which allows internal co-molded composite assemblies. This approach results in composite structures which require no secondary operations and reduces unit costs to the customer. Innovative tooling consisting of a hybrid design combining the best elements of the trapped rubber and bladder molding system produce products which exceed their requirements and are consistently reproduced.

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 and improved manufacturing consistency and reduces unit costs.

Encapsulation
Our Oceanside, California facility features work space specifically devoted to the encapsulation of electronic assemblies and electromagnetic coils. The 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.

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Carbon by Design maintains an ISO 9001 Compliant Quality Management System and has been independently audited and qualified.