FLYING HIGH – NEXT LEVEL METAL AND COMPOSITE MANUFACTURING FOR THE AEROSPACE INDUSTRY
FLYING HIGH – NEXT LEVEL METAL AND COMPOSITE MANUFACTURING FOR THE AEROSPACE INDUSTRY
Armstrong Group are committed to pushing the boundaries of aerospace component manufacturing technology. With many years of experience, we have established ourselves as a leader in the manufacturing of both metal and composite components for the aerospace industry.
Our dedicated team of engineers, designers and technicians are passionate about creating solutions that meet the highest industry standards for safety, quality and performance. We pride ourselves on our ability to deliver components that are lightweight, durable and engineered for the extremely demanding modern aviation industry. Our mission is to support our clients in building the future of flight.
Armstrong Group are committed to pushing the boundaries of aerospace component manufacturing technology. With many years of experience, we have established ourselves as a leader in the manufacturing of both metal and composite components for the aerospace industry.
Our dedicated team of engineers, designers and technicians are passionate about creating solutions that meet the highest industry standards for safety, quality and performance. We pride ourselves on our ability to deliver components that are lightweight, durable and engineered for the extremely demanding modern aviation industry. Our mission is to support our clients in building the future of flight.
Metal And Composites Aerospace Component Manufacturing
Metal And Composites Aerospace Component Manufacturing
Aluminium Aircraft Nacelles
Aircraft nacelles are streamlined enclosures that house the engine, playing a crucial role in aerodynamic efficiency, noise reduction and internal engine component protection. As the modern aviation industry constantly strives to produce lighter, more fuel-efficient aircraft, using aluminum to manufacture aircraft nacelles is increasingly being viewed as the best solution due to the balance between strength and weight, its resistance to corrosion and its excellent thermal conductivity.
Sustainability in Aluminum Nacelle Manufacturing
In addition to performance benefits, the use of aluminum in nacelle manufacturing supports environmental sustainability. Aluminum is highly recyclable, and the aviation industry is increasingly focusing on reducing waste and energy consumption during production. This aligns with the sector’s goals to minimise its environmental impact while improving fuel efficiency.
1) Choosing the right alloy: Common aluminium alloys specified by customers are 2024, 6061 and 7075 alloys, which offer a balance between weight, strength and resistance to the environment.
2) Forming: The aluminum sheets are shaped into the nacelle’s components by the Armstrong team using on-site state of the art metal forming processes.
3) Machining: Precision is crucial in nacelle manufacturing. Processes including CNC milling, drilling and laser cutting are used to produce exact components, including the inlet lips, acoustic liners and structural support frames.
4) Joining and Assembly: Aluminum parts are joined using processes including friction stir welding and riveting. These methods ensure robust connections that can withstand the mechanical and thermal stresses of flight.
5) Surface Treatment: To enhance the natural corrosion resistance of aluminum, additional protective coatings are applied, such as anodising or alodining.
6) Acoustic and Thermal Insulation: Aluminum nacelles often feature integrated acoustic liners to dampen noise produced by the engine. Advanced thermal insulation materials are embedded into the nacelle to protect it from the extreme heat generated by jet engines.
7) Quality Assurance: Before assembly, each part of the nacelle undergoes a detailed laser scanning measurement process to ensure adherence to very tight tolerances.
Aluminium Aircraft Nacelles
Aircraft nacelles are streamlined enclosures that house the engine, playing a crucial role in aerodynamic efficiency, noise reduction and engine internal component protection. As the modern aviation industry constantly strives to produce lighter, more fuel-efficient aircraft, aluminum nacelles have emerged as an excellent solution due to the balance between strength, weight and resistance to corrosion.
Sustainability in Aluminum Nacelle Manufacturing
In addition to performance benefits, the use of aluminum in nacelle manufacturing supports environmental sustainability. Aluminum is highly recyclable, and the aviation industry is increasingly focusing on reducing waste and energy consumption during production. This aligns with the sector’s goals to minimise its environmental impact while improving fuel efficiency.
1) Choosing the right alloy: Common aluminium alloys specified by customers are 2024, 6061 and 7075 alloys, which offer a balance between weight, strength and resistance to the environment.
2) Forming: The aluminum sheets are shaped into the nacelle’s components by the Armstrong team using on-site state of the art metal forming processes.
3) Machining: Precision is crucial in nacelle manufacturing. Processes including CNC milling, drilling and laser cutting are used to produce exact components, including the inlet lips, acoustic liners and structural support frames.
4) Joining and Assembly: Aluminum parts are joined using processes including friction stir welding and riveting. These methods ensure robust connections that can withstand the mechanical and thermal stresses of flight.
5) Surface Treatment: To enhance the natural corrosion resistance of aluminum, additional protective coatings are applied, such as anodising or alodining.
6) Acoustic and Thermal Insulation: Aluminum nacelles often feature integrated acoustic liners to dampen noise produced by the engine. Advanced thermal insulation materials are embedded into the nacelle to protect it from the extreme heat generated by jet engines.
7) Quality Assurance: Before assembly, each part of the nacelle undergoes a detailed laser scanning measurement process to ensure adherence to very tight tolerances.
Carbon Fibre Engine Blades
The Future of Aircraft Engine Efficiency
Innovation drives progress in the aerospace component manufacturing sector and one of the most exciting advancements in recent years has been the development of carbon fibre turbine blades for aircraft engines. As OEMs strive to enhance performance, reduce weight and improve fuel efficiency, carbon fibre has emerged as a game-changer, offering significant advantages over traditional turbine blade materials such as titanium and nickel alloys.
Carbon fibre has an exceptional strength-to-weight ratio, durability and excellent resistance to high temperature environments. When used in turbine blades, this material can withstand the extreme forces and temperatures within aircraft engines, while offering weight reduction. This is crucial because reducing the weight of rotating components within an engine leads to improved fuel efficiency and better performance.
The process of creating carbon fibre turbine blades involves several stages of precision engineering:
Material Selection: High-quality carbon fibre construction materials are selected based on their strength, flexibility and heat resistance properties. These fibres are woven into a fabric or unidirectional tape that serves as the structural framework of the blade.
Layup Process: The carbon fibre material is layered in a precise orientation to achieve the desired strength and structural integrity. The layers are then combined with a resin that acts as a binder to create a solid composite material.
Curing: After the layup, the turbine blades are placed into our autoclave where heat and pressure are applied to form a hardened, durable structure. This step ensures the carbon fibre bonds properly, giving the blade its final shape and strength.
Machining and Finishing: Once cured, the blades are trimmed, polished and machined to meet the exact specifications required for the aeroplane engine. This step ensures that the blades meet precise aerodynamic and performance criteria.
Quality Testing: The finished blades are checked and measured using our laser scanning equipment. This ensures that they meet the high tolerance standards required by OEM’s in the aerospace industry.
Carbon Fibre Engine Blades
The Future of Aircraft Engine Efficiency
Innovation drives progress in the aerospace component manufacturing sector and one of the most exciting advancements in recent years has been the development of carbon fibre turbine blades for aircraft engines. As OEMs strive to enhance performance, reduce weight and improve fuel efficiency, carbon fibre has emerged as a game-changer, offering significant advantages over traditional turbine blade materials such as titanium and nickel alloys.
Carbon fibre has an exceptional strength-to-weight ratio, durability and excellent resistance to high temperature environments. When used in turbine blades, this material can withstand the extreme forces and temperatures within aircraft engines, while offering weight reduction. This is crucial because reducing the weight of rotating components within an engine leads to improved fuel efficiency and better performance.
The process of creating carbon fibre turbine blades involves several stages of precision engineering:
Material Selection: High-quality carbon fibre construction materials are selected based on their strength, flexibility and heat resistance properties. These fibres are woven into a fabric or unidirectional tape that serves as the structural framework of the blade.
Layup Process: The carbon fibre material is layered in a precise orientation to achieve the desired strength and structural integrity. The layers are then combined with a resin that acts as a binder to create a solid composite material.
Curing: After the layup, the turbine blades are placed into our autoclave where heat and pressure are applied to form a hardened, durable structure. This step ensures the carbon fibre bonds properly, giving the blade its final shape and strength.
Machining and Finishing: Once cured, the blades are trimmed, polished and machined to meet the exact specifications required for the aeroplane engine. This step ensures that the blades meet precise aerodynamic and performance criteria.
Quality Testing: The finished blades are checked and measured using our laser scanning equipment. This ensures that they meet the high tolerance standards required by OEM’s in the aerospace industry.
Composite Aircraft Cockpit And Cabin Trim
Composite materials have revolutionised the aerospace industry, especially in the manufacturing of aircraft cockpit and cabin trims. Armstrong Group are experts in manufacturing using lightweight, durable materials which provide numerous advantages in aircraft interior applications, ensuring that passenger safety and comfort requirements are met, while also contributing to the overall efficiency and aesthetics of the aircraft.
We design and manufacture components including sidewalls, ceiling panels, window reveals, seat backs and other aesthetic or protective elements inside the aircraft. The use of composites in manufacturing of these components has become prevalent due to their exceptional strength-to-weight ratio.
1) Material Selection
The choice of composite materials for cockpit and cabin trim components is driven by weight, durability, flammability standards and environmental factors. Armstrong commonly use composites including:
Carbon fibre-reinforced polymers (CFRP)
Glass fibre-reinforced polymers (GFRP)
Aramid fibres (such as Kevlar)
All of these materials offer high strength, corrosion resistance and significant weight savings compared to traditionally used materials such as aluminum or steel.
2) Design & Engineering
The design of aircraft cabin trim starts with CAD modeling, where each aspect of the component is engineered for precision and compliance with rigorous aerospace OEM standards. 3D design simulations allow our team to test components under various environmental conditions such as pressure changes, vibrations and heat exposure, all while ensuring minimal weight.
3) Composite Layup Process
The composite layup process involves placing layers of fibre sheets in a mould, with each layer oriented in specific directions to optimise final component strength. These layers are then saturated with a resin (epoxy or polyester), which, when cured, forms a solid, durable structure. The processes used by our composites team are:
Hand Layup – A manual process where each layer is placed by hand, ideal for small production runs or custom components.
Automated Layup: Automated machines precisely place the fibres in predetermined directions, offering high precision and consistency for large-scale production.
4) Curing Process
After the layup is completed, the composite part undergoes curing, where heat and pressure are applied to solidify the resin matrix. This is done using our on-site Autoclave; a pressurized chamber that applies both heat and pressure to ensure the strongest, most reliable bonds.
5) Trimming & Assembly
Once the composite part is cured, it is removed from the mould and any excess material is trimmed using our CNC machines, ensuring that each piece is cut to exact dimensions. The parts are then sent to our customers for assembly into the larger aircraft interior structure.
6) Finishing & Quality Control
Each component is finished with surface treatments including painting, or coating to improve appearance and durability. They are then measured using a laser scanning system to ensure their dimensional accuracy. Aircraft cabin trim components must undergo rigorous quality control processes, including testing for fire and impact resistance. Meeting stringent aviation regulatory standards such as FAR 25.853 for flammability is critical.
Composite Aircraft Cockpit And Cabin Trim
Composite materials have revolutionised the aerospace industry, especially in the manufacturing of aircraft cockpit and cabin trims. Armstrong Group are experts in manufacturing using lightweight, durable materials which provide numerous advantages in aircraft interior applications, ensuring that passenger safety and comfort requirements are met, while also contributing to the overall efficiency and aesthetics of the aircraft.
We design and manufacture components including sidewalls, ceiling panels, window reveals, seat backs and other aesthetic or protective elements inside the aircraft. The use of composites in manufacturing of these components has become prevalent due to their exceptional strength-to-weight ratio.
1) Material Selection
The choice of composite materials for cockpit and cabin trim components is driven by weight, durability, flammability standards and environmental factors. Armstrong commonly use composites including:
Carbon fibre-reinforced polymers (CFRP)
Glass fibre-reinforced polymers (GFRP)
Aramid fibres (such as Kevlar)
All of these materials offer high strength, corrosion resistance and significant weight savings compared to traditionally used materials such as aluminum or steel.
2) Design & Engineering
The design of aircraft cabin trim starts with CAD modeling, where each aspect of the component is engineered for precision and compliance with rigorous aerospace OEM standards. 3D design simulations allow our team to test components under various environmental conditions such as pressure changes, vibrations and heat exposure, all while ensuring minimal weight.
3) Composite Layup Process
The composite layup process involves placing layers of fibre sheets in a mould, with each layer oriented in specific directions to optimise final component strength. These layers are then saturated with a resin (epoxy or polyester), which, when cured, forms a solid, durable structure. The processes used by our composites team are:
Hand Layup – A manual process where each layer is placed by hand, ideal for small production runs or custom components.
Automated Layup: Automated machines precisely place the fibres in predetermined directions, offering high precision and consistency for large-scale production.
4) Curing Process
After the layup is completed, the composite part undergoes curing, where heat and pressure are applied to solidify the resin matrix. This is done using our on-site Autoclave; a pressurized chamber that applies both heat and pressure to ensure the strongest, most reliable bonds.
5) Trimming & Assembly
Once the composite part is cured, it is removed from the mould and any excess material is trimmed using our CNC machines, ensuring that each piece is cut to exact dimensions. The parts are then sent to our customers for assembly into the larger aircraft interior structure.
6) Finishing & Quality Control
Each component is finished with surface treatments including painting, or coating to improve appearance and durability. They are then measured using a laser scanning system to ensure their dimensional accuracy. Aircraft cabin trim components must undergo rigorous quality control processes, including testing for fire and impact resistance. Meeting stringent aviation regulatory standards such as FAR 25.853 for flammability is critical.
Aluminium And Composite Aircraft Seat Components
Aircraft seat manufacturing is a critical aspect of aviation, balancing passenger comfort and safety while contributing to the overall fuel efficiency of the aircraft through the application of lightweight materials. Modern commercial and private aircraft seating involves a combination of lightweight aluminum and advanced composite materials to meet the high specifications demanded by aerospace OEMs.
Aluminum is a preferred material in aircraft seating frames due to its excellent strength-to-weight ratio. It offers high durability while being lightweight, which is crucial for fuel efficiency in aviation.
Composite materials offer unmatched weight savings and design flexibility in aerospace component manufacturing, allowing the Armstrong team to create seat components that are not only lighter but also ergonomic and visually appealing.
The Manufacturing Process
Composite Layup: Thin layers of carbon fibre are initially arranged in precise orientations and infused with resin to form a strong, lightweight composite material.
Moulding: The composite layup is placed into moulds and then subjected to heat and pressure in our on-site autoclave, creating the final seat components.
Finishing and Assembly: Once cured, composite parts are then assembled with other components such as metal fasteners or additional cushioning. The final product is then painted or coated.
Advantages
Ultra-Lightweight: Composites significantly reduce seat weight, contributing to fuel savings and increased aircraft range.
Strength and Flexibility: Despite being lightweight, composites are incredibly strong and can be moulded into intricate designs for improved passenger comfort.
Fatigue and Corrosion Resistance: Composite materials are highly resistant to wear, environmental degradation and fatigue, ensuring excellent long-term performance.
Safety and Comfort: Key Considerations in Aircraft Seat Design.
In addition to weight reduction, the team at Armstrong consider passenger comfort and safety. Modern aircraft seats must meet stringent safety regulations, including crashworthiness tests that assess the seat’s ability to protect passengers in an emergency.
Comfort Features
Ergonomics: Seat design is optimised for long-haul flights, offering better body support and adjustability.
Modularity: Seats are designed to be modular, allowing easy customisation for different cabin classes (economy, business, first class).
Safety Standards
Crash Testing: The seat design will undergo rigorous testing, including dynamic testing to simulate crash scenarios, ensuring they meet FAA and EASA safety standards. Computer simulations are used to test seats before a design moves to the physical prototype stage, and once a design is approved, the final physical seat will undergo rigorous testing by the OEM.
Fire Resistance: Materials used adhere to strict flammability tests to ensure passenger safety in the event of a fire.
Sustainability and Innovation in Aircraft Seating
As the aerospace industry focuses more on sustainability, Armstrong are also constantly looking at ways to improve the environmental impact of our products. This includes using recyclable materials, improving manufacturing efficiency and exploring greener production techniques.
Eco-Friendly Composites
Bio-Based Resins: Our team are experimenting with bio-based resins in composite materials, to reduce reliance on petroleum-based products.
Recyclable Aluminium Alloys: We are also involved with material suppliers where advanced aluminium alloys are being developed that are easier to recycle, promoting a circular economy within the aerospace industry.
Aluminium And Composite Aircraft Seat Components
Aircraft seat manufacturing is a critical aspect of aviation, balancing passenger comfort and safety while contributing to the overall fuel efficiency of the aircraft through the application of lightweight materials. Modern commercial and private aircraft seating involves a combination of lightweight aluminum and advanced composite materials to meet the high specifications demanded by aerospace OEMs.
Aluminum is a preferred material in aircraft seating frames due to its excellent strength-to-weight ratio. It offers high durability while being lightweight, which is crucial for fuel efficiency in aviation.
Composite materials offer unmatched weight savings and design flexibility in aerospace component manufacturing, allowing the Armstrong team to create seat components that are not only lighter but also ergonomic and visually appealing.
The Manufacturing Process
Composite Layup: Thin layers of carbon fibre are initially arranged in precise orientations and infused with resin to form a strong, lightweight composite material.
Moulding: The composite layup is placed into moulds and then subjected to heat and pressure in our on-site autoclave, creating the final seat components.
Finishing and Assembly: Once cured, composite parts are then assembled with other components such as metal fasteners or additional cushioning. The final product is then painted or coated.
Advantages
Ultra-Lightweight: Composites significantly reduce seat weight, contributing to fuel savings and increased aircraft range.
Strength and Flexibility: Despite being lightweight, composites are incredibly strong and can be moulded into intricate designs for improved passenger comfort.
Fatigue and Corrosion Resistance: Composite materials are highly resistant to wear, environmental degradation and fatigue, ensuring excellent long-term performance.
Safety and Comfort: Key Considerations in Aircraft Seat Design.
In addition to weight reduction, the team at Armstrong consider passenger comfort and safety. Modern aircraft seats must meet stringent safety regulations, including crashworthiness tests that assess the seat’s ability to protect passengers in an emergency.
Comfort Features
Ergonomics: Seat design is optimised for long-haul flights, offering better body support and adjustability.
Modularity: Seats are designed to be modular, allowing easy customisation for different cabin classes (economy, business, first class).
Safety Standards
Crash Testing: The seat design will undergo rigorous testing, including dynamic testing to simulate crash scenarios, ensuring they meet FAA and EASA safety standards. Computer simulations are used to test seats before a design moves to the physical prototype stage, and once a design is approved, the final physical seat will undergo rigorous testing by the OEM.
Fire Resistance: Materials used adhere to strict flammability tests to ensure passenger safety in the event of a fire.
Sustainability and Innovation in Aircraft Seating
As the aerospace industry focuses more on sustainability, Armstrong are also constantly looking at ways to improve the environmental impact of our products. This includes using recyclable materials, improving manufacturing efficiency and exploring greener production techniques.
Eco-Friendly Composites
Bio-Based Resins: Our team are experimenting with bio-based resins in composite materials, to reduce reliance on petroleum-based products.
Recyclable Aluminium Alloys: We are also involved with material suppliers where advanced aluminium alloys are being developed that are easier to recycle, promoting a circular economy within the aerospace industry.
Aluminium And Composite Aircraft Storage Lockers
Aircraft storage lockers play a crucial role in ensuring that airlines are able to maintain a clutter-free and organised cabin space. These lockers, typically installed in various compartments of the aircraft, are used for storing flight crew equipment and emergency supplies, with overhead lockers storing passenger belongings.
At Armstrong we design and manufacture modern aircraft lockers using advanced materials including aluminium and composite materials, to meet the exact specifications of aerospace OEMs. By utilising these materials Armstrong are able to deliver lockers that are lightweight, durable and capable of withstanding the rigors of modern air travel. This not only enhances aircraft performance and fuel efficiency but also ensures passenger and crew safety through reliable storage solutions.
Aluminium Aircraft Storage Lockers
Aluminium has long been a favorite material in aerospace due to its excellent balance of strength, weight and resistance to corrosion. When it comes to aircraft storage lockers, aluminium offers the following benefits:
Lightweight: Weight is a crucial consideration in aircraft design, and aluminium is significantly lighter than many other metals, reducing the overall aircraft weight and improving fuel efficiency.
Corrosion-resistance: Aircraft lockers must withstand fluctuating temperatures and humidity levels, making aluminium’s natural resistance to corrosion vital for long-term durability.
High Strength-to-Weight Ratio: Aluminium provides the necessary structural strength to endure the constant use and movement of items stored within the lockers.
Recyclable: Aluminium is highly recyclable, making it a sustainable choice for aerospace OEMs aiming to reduce their environmental footprint.
The Manufacturing Process
Material Selection: High-quality, aircraft-grade aluminium sheets or panels are used at Armstrong, for locker construction. The particular material undergoes stringent testing for strength and durability.
Cutting and Shaping: Using our onsite precision CNC machining cells, the aluminium sheets are cut to the required dimensions. Complex shapes and custom designs are crafted with precision to ensure the lockers fit within specific aircraft spaces.
Assembly: The individual panels are assembled using aerospace-grade fasteners and welding techniques. Hinges, locks, and other components are securely attached.
Surface Treatment: The final product undergoes anodizing or powder coating for additional corrosion resistance and aesthetics, ensuring the locker matches the aircraft’s interior design while maintaining durability.
Composite Aircraft Storage Lockers
Composite materials are increasingly being specified by OEMs for aircraft storage lockers due to their superior strength, flexibility and lightweight properties. Composites offer unique benefits that make them a preferred choice in many modern aircraft.
Ultra-Lightweight: Composites can be up to 50% lighter than traditional aluminium, contributing significantly to fuel savings and enhancing aircraft performance.
Enhanced Durability: Composite materials are highly resistant to wear, impact and corrosion, ensuring a long lifespan even under tough conditions.
Design Flexibility: Composites allow for greater design innovation, enabling complex shapes and streamlined designs that can optimize space utilisation in aircraft cabins.
Thermal Stability: Composite materials maintain their integrity under high temperatures, making them well-suited for the demanding environments encountered in flight.
Manufacturing Process
Material Preparation: Layers of carbon fibre or glass fibre are impregnated with a resin matrix, usually epoxy or similar, to form the base composite material.
Moulding and Shaping: The composite material is layered into moulds designed for specific locker shapes. Using our on-site autoclave, the material is cured under high pressure and temperature to harden the material and achieve its final shape.
Trimming and Assembly: Once cured, the composite parts are trimmed to exact specifications using high precision laser cutting machines. Locking mechanisms, hinges and other hardware are then installed.
Finishing and Quality Control: The surface of the composite lockers is treated for fire resistance and UV protection. Rigorous testing is conducted to ensure compliance with safety and weight standards.
The Advantages of Combining Aluminium and Composite Materials
At Armstrong, some aircraft storage lockers are designed using a hybrid approach, combining aluminium with composite materials to leverage the strengths of both materials.
Weight Reduction: Using composites in specific areas can reduce the overall locker weight without compromising on structural integrity.
Enhanced Durability: Aluminium is used in areas that require additional impact resistance, while composites are used in sections that benefit from reduced weight.
Optimised Cost: A combination of materials allows manufacturers to balance cost efficiency with performance, as aluminium tends to be less expensive than high-performance composites.
Aluminium And Composite Aircraft Storage Lockers
Aircraft storage lockers play a crucial role in ensuring that airlines are able to maintain a clutter-free and organised cabin space. These lockers, typically installed in various compartments of the aircraft, are used for storing flight crew equipment and emergency supplies, with overhead lockers storing passenger belongings.
At Armstrong we design and manufacture modern aircraft lockers using advanced materials including aluminium and composite materials, to meet the exact specifications of aerospace OEMs. By utilising these materials Armstrong are able to deliver lockers that are lightweight, durable and capable of withstanding the rigors of modern air travel. This not only enhances aircraft performance and fuel efficiency but also ensures passenger and crew safety through reliable storage solutions.
Aluminium Aircraft Storage Lockers
Aluminium has long been a favorite material in aerospace due to its excellent balance of strength, weight and resistance to corrosion. When it comes to aircraft storage lockers, aluminium offers the following benefits:
Lightweight: Weight is a crucial consideration in aircraft design, and aluminium is significantly lighter than many other metals, reducing the overall aircraft weight and improving fuel efficiency.
Corrosion-resistance: Aircraft lockers must withstand fluctuating temperatures and humidity levels, making aluminium’s natural resistance to corrosion vital for long-term durability.
High Strength-to-Weight Ratio: Aluminium provides the necessary structural strength to endure the constant use and movement of items stored within the lockers.
Recyclable: Aluminium is highly recyclable, making it a sustainable choice for aerospace OEMs aiming to reduce their environmental footprint.
The Manufacturing Process
Material Selection: High-quality, aircraft-grade aluminium sheets or panels are used at Armstrong, for locker construction. The particular material undergoes stringent testing for strength and durability.
Cutting and Shaping: Using our onsite precision CNC machining cells, the aluminium sheets are cut to the required dimensions. Complex shapes and custom designs are crafted with precision to ensure the lockers fit within specific aircraft spaces.
Assembly: The individual panels are assembled using aerospace-grade fasteners and welding techniques. Hinges, locks, and other components are securely attached.
Surface Treatment: The final product undergoes anodizing or powder coating for additional corrosion resistance and aesthetics, ensuring the locker matches the aircraft’s interior design while maintaining durability.
Composite Aircraft Storage Lockers
Composite materials are increasingly being specified by OEMs for aircraft storage lockers due to their superior strength, flexibility and lightweight properties. Composites offer unique benefits that make them a preferred choice in many modern aircraft.
Ultra-Lightweight: Composites can be up to 50% lighter than traditional aluminium, contributing significantly to fuel savings and enhancing aircraft performance.
Enhanced Durability: Composite materials are highly resistant to wear, impact and corrosion, ensuring a long lifespan even under tough conditions.
Design Flexibility: Composites allow for greater design innovation, enabling complex shapes and streamlined designs that can optimize space utilisation in aircraft cabins.
Thermal Stability: Composite materials maintain their integrity under high temperatures, making them well-suited for the demanding environments encountered in flight.
Manufacturing Process
Material Preparation: Layers of carbon fibre or glass fibre are impregnated with a resin matrix, usually epoxy or similar, to form the base composite material.
Moulding and Shaping: The composite material is layered into moulds designed for specific locker shapes. Using our on-site autoclave, the material is cured under high pressure and temperature to harden the material and achieve its final shape.
Trimming and Assembly: Once cured, the composite parts are trimmed to exact specifications using high precision laser cutting machines. Locking mechanisms, hinges and other hardware are then installed.
Finishing and Quality Control: The surface of the composite lockers is treated for fire resistance and UV protection. Rigorous testing is conducted to ensure compliance with safety and weight standards.
The Advantages of Combining Aluminium and Composite Materials
At Armstrong, some aircraft storage lockers are designed using a hybrid approach, combining aluminium with composite materials to leverage the strengths of both materials.
Weight Reduction: Using composites in specific areas can reduce the overall locker weight without compromising on structural integrity.
Enhanced Durability: Aluminium is used in areas that require additional impact resistance, while composites are used in sections that benefit from reduced weight.
Optimised Cost: A combination of materials allows manufacturers to balance cost efficiency with performance, as aluminium tends to be less expensive than high-performance composites.