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Capabilities

AEROSPACE COMPOSITES

Capabilities

Aerospace Composites facility was established in 2018 to complement the existing metallic capabilities to cater to the growing demands in Aerospace sector. The facility is laid out on nearly 7450 square meter area in U-flow pattern to facilitate smooth process flow integrating all activities from storage of raw material to assembly of large structures under one roof. The facility has been comprehensively planned to provide industrial partnership to the Space, Defence and Aviation endeavors of the country as well as to compete in Global Aerospace Arena.

ATC Composites facility has been accredited with AS 9100D and NADCAP. Highly proficient and experienced human resource in composite manufacturing adds to the core strength of our organization. LMW composites team is being equipped to Design, Develop, Qualify and Manufacture the structural products from given configurational definition and load spectrum.





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Major Highlights

The State-of-the-Art facility is comprehensively equipped to manufacture structural composites parts, sub-assemblies and assemblies for Aerospace and Defence applications. The Facility is equipped with

  • Cold storage (-20℃ ± 2℃)
  • Clean Room – Low Bay: Height – 6m, Area: 400 square meters, ISO Class 8 (Convertible to ISO Class 7)
  • Clean Room – High Bay: Height – 12m equipped with 10T EOT Crane. Area: 600 square meters, ISO Class 8
  • Universal Testing Machine: Capacity – 100kN
  • CNC Prepreg Cutting Machine
  • Autoclave 1: 1.3 m Dia and 2.4 m length, Temperature: 450℃, Pressure: 15 Bar
  • Autoclave 2: 4 m Dia and 6 m length, Temperature: 250℃, Pressure: 10 Bar
  • NDT: Sophisticated C-Scan from Scan Master – 10 Axis : Dry & Wet probes of size 7m x 2m x 3m
  • NDT: A-Scan, Phased Array Ultrasonic Testing equipment
  • Resin Transfer Moulding & Vacuum Infusion Moulding
  • High assembly bay of 1870 square meters (Size – 85 m x 22 m x 22 m) equipped with two cranes, 10T crane at 18m level and 5T crane at 10m level
  • Hot Air Oven: Size – 6 m x 4 m x 3.5 m

Facility

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    Cold storage

    • Cold storage is meant to store the prepreg adhesives and associated materials for composite products at -20℃ ± 2℃ to set the best potential out of them.
    • Size = 7m Length x 3.9m Breadth x 3m Height
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    Universal Testing Machine

    • 100 KN INSTRON UTM is deployed to carry out acceptance test to incoming materials as well as characterization of material properties for design inputs.
    • It is proposed to be equipped to find out properties at temperature of -120℃ to +250℃.
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    Clean Room

    Low bay

    • The processing area comprising two clean rooms one of ISO class 7 another of ISO class 8 level of cleanliness is the nerve center of the facilities.
    • ISO Class 7 cleanroom Area - 400sq. meters
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    Clean Room

    High bay

    • The processing area comprising two clean rooms one of ISO class 7 another of ISO class 8 level of cleanliness is the nerve center of the facilities.
    • ISO Class 8 cleanroom Area - 600sq. meters
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    Prepreg Cutting machine

    • Lectra CNC prepreg cutting machine is used to create ply clips with higher nesting efficiency to conserve material.
    • Size = 1.7m Length x 1.82m Breadth
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    Autoclave 1

    • The facility equipped with two autoclaves to cure the laid-up products. This computer-controlled autoclave is linked to digital data accusation system to provide comprehensive cure cycle data for product data package.
    • 1.3m Diameter x 2.4m Length
    • Pressure = 15 Bar; Temperature = 450℃.
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    Autoclave 2

    • The facility equipped with two autoclaves to cure the laid-up products. This computer-controlled autoclave is linked to digital data accusation system to provide comprehensive cure cycle data for product data package.
    • 4.0m Diameter x 6.0m Length
    • Pressure = 10 Bar; Temperature = 250℃.
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    CMM

    CNC 3D Coordinate Measuring Machine available in metallics vertical is being shared for dimensional inspection of composite products.

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    Laser tracker

    Laser Tracker will be used for calibration of large assembly kits as well as inspection of the assembly structures.

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    NDT

    The facility is equipped with sophisticated C-Scan from Scan Master – 10 Axis : Dry & Wet probes of size 7m x 2m x 3m

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    ASSEMBLY HIGH BAY

    High assembly bay of 1870 square meters (Size – 85 m x 22 m x 22 m) is equipped with two cranes - 10T crane at 18 metre level and 5T crane at 10 metre level to handle large aerospace structures.

Composite Products to Demonstrate Capability

  • ATC C Frame
  • ATC CFRP Tube
  • ATC Hat Stiffened Cylindrical Shell Assembly
  • ATC Proof of Concept for Optical Structure
  • ATC Proof of Concept for Small Satellite Mounting Structure
  • ATC Sandwich Dish Panel
  • ATC Satellite Deployer

Composite Products Realised and being Realised

  • ATC 2m Dia Interstage Structure for SSLV
  • ATC 4m Dia Hat Stiffened Structure for GSLV MkIII
  • ATC 90 deg sector Stiffened Structure for GSLV MkIII
  • ATC Antenna Reflector
  • ATC Boat Tail Panel
  • ATC Cowling Control Assembly
  • ATC Cowling Top Engine
  • ATC Fork Side Cover for UAV
  • ATC Nose Cap Panel
  • ATC 5m Dia and 10.7m Height Payload Fairing for GSLV MkIII
  • ATC Seal Support Assembly for ALH

Product Portfolio in our vision

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Space and Defence Components

  • Pay load fairings
  • Composite interstage structures
  • Radomes for space, airborne and ground applications
  • Antenna reflectors
  • Solar panel substrates
  • Pressure vessels
  • Motor cases
  • Missile launcher tubes

Fixed-Wing Aircraft Components

  • Fuselage components
  • Fin and Rudder
  • Interior components
  • Floor beams and panels
  • Fixed wing structures
  • Flaps, Ailerons and Spoilers
  • Engine nacelles

Rotary-Wing Aircraft Components

  • Main rotor blade and Hub plate
  • Tail rotor blade and Hub plate
  • Door assembly and interiors
  • Engine cowlings
  • Landing skids
  • Empennage components