Development and manufacture of carbon fibre composite components for aerospace using filament winding technology

AEROSPACE COMPOSITES GmbH

Laupheim (Headquarters) · MemmingerbergNew on Amplifa

24Employees

5,500 m²Production area Laupheim

2.5 m diameter / 22 m lengthMax. wound components

1,900Approved drawings

7Approved (S)TCs

About Aerospace Composites

Aerospace Composites GmbH, headquartered in Laupheim, specialises in the research, development and manufacture of highly complex components for the global aerospace industry. Its core competence is filament winding technology: carbon and glass fibres are wound under controlled tension around a rotating mandrel and subsequently cured in an autoclave or oven. Products include engine components made of heat-resistant carbon composites, aircraft structures such as wing parts and fuselage segments, pressure vessels and fuel tanks for launch vehicles and satellites, as well as rotor blades and cylinders for helicopters. The winding system processes parts up to 2.5 m in diameter and 22 m in length; the portfolio is complemented by automated 3D printing processes and metal processing. As a certified EASA 21J design organisation (EASA.21J.551), the company is qualified for the design and approval of small aircraft in accordance with CS-23 and develops supplementary supplemental type certificates (STC), among others for the Daher/Quest Kodiak 100. 24 employees work on a production area of 5,500 m²; the company holds 1,900 approved drawings.

Site: Laupheim
Processes: Filament winding technology, Curing of composite components in autoclave or oven, Manufacture of carbon components for aerospace (e.g. engine components), Automated 3D printing processes, Metal processing, Research, development and certification (EASA 21J design organisation, CS-23, supplemental, Product support, service bulletins, spare parts supply, safety management (airworthiness), Filament winding technology (carbon/glass fibre, autoclave/oven curing)
Materials: Carbon fibres / CFRP (carbon fibre reinforced plastics), Heat-resistant carbon composites, Glass fibre, Metals (metal processing, material not further specified), Carbon fibre reinforced plastics (CFRP), Metals
Certificates: EASA 21J design organisation (DOA, EASA.21J.551), EASA 21J design organisation (EASA.21J.551, CS-23)
Employees: 24
Industries: Aerospace, Special missions/ISR, Engine manufacturing, Space (launch vehicles, satellites), Helicopters, Special missions/ISR (cartography, surveillance)

01
Design and development (EASA 21J design organisation)
02
Filament winding technology (carbon/glass fibre)
03
Curing in autoclave or oven
04
3D printing and metal processing (supplementary)
05
Certification (STC, CS-23)
06
Product support, service bulletins and safety management

Materials and Processes

CFK

Carbon fibre reinforced plastics (CFRP)

Lightweight material with high strength and stiffness for aircraft structures, engine and rocket parts.

C/C

Heat-resistant carbon composites

Used in engine components to withstand high temperatures.

Glass fibre

Supplementary fibre composite material in filament winding for component-specific requirements.

Metals

Metal processing as a supplementary manufacturing competence alongside the fibre composite materials.

Locations

Laupheim

Headquarters, production

Part weight / size: Wound components up to 2.5 m diameter and 22 m length
Materials: Carbon (CFRP), glass fibre, heat-resistant carbon composites

Filament winding machine
Autoclave
Curing oven

Memmingerberg

Site Am Flughafen 12A (design organisation/support)

Components and Certifications

**Battery modification Kodiak 100 (STC)**Design/certification · Aviation

**Single door Kodiak 100 (fuselage cut-out with sliding door)**Design/certification · Special missions

**Cartography aircraft Kodiak 100**STC · Cartography

**Patrol aircraft Kodiak 100**STC · ISR/surveillance

**External ISR equipment Kodiak 100 (radome, lift system)**STC · ISR

Inside the production

Industries

AerospaceSpecial missions/ISREngine manufacturingSpace (launch vehicles, satellites)HelicoptersSpecial missions/ISR (cartography, surveillance)

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Filament winding technologyPlastics	–	22m × 2.5 m diameter	–	–	Carbon (CFRP), Glass fibre
Curing of composite components in autoclave or ovenPlastics	–	–	–	–	Carbon, Glass fibre, Carbon composites
Manufacture of carbon components for aerospace (e.g. engine components)Plastics	–	–	–	–	heat-resistant carbon composites, carbon fibres, CFRP
Automated 3D printing processesAdditive	–	–	–	–	Carbon
Metal processingMachining	–	–	–	–	Metals
Research, development and certification (EASA 21J design organisation, CS-23, supplementalEngineering	–	–	–	–	–
Product support, service bulletins, spare parts supply, safety management (airworthiness)Assembly	–	–	–	–	–

3 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
Filament winding machine (automated winding processes)	–	–	Wound parts up to 2.5 m diameter and 22 m length	–	Laupheim
Autoclave	–	–	–	–	Laupheim
Curing oven	–	–	–	–	Laupheim

Additional services

Filament winding technology (carbon/glass fibre, autoclave/oven curing)Manufacture of carbon components for aerospace (engine components, aircraft structures)Research & development / engineeringDevelopment and certification of supplemental type certificates (STC)Type certificate holder of the Extra 400 & 500 (airworthiness)Product support: manuals, service bulletins, spare parts requests, change of ownershipMetal processing and fibre composite materials

Reference customers

Daher/Quest Kodiak 100 operators (STC platform)

Quality and Airworthiness

As a certified EASA 21J design organisation (EASA.21J.551), the company meets the requirements for the design and approval of small aircraft in accordance with CS-23. An implemented safety management system as well as product support with service bulletins and mandatory occurrence reporting ensure the maintenance of airworthiness.

Evidence	Laupheim
EASA 21J design organisation (EASA.21J.551, CS-23)