Composite Design & Fabrication

Calspan has provided composite design and fabrication of composite components to both the Aerospace and Marine industries for more than 25 years. Our expertise in rapid design and manufacturing techniques provides a cost effective solution for the development of prototype and low to medium production composite components and systems. Our facility and equipment allow us to manufacture composite tooling in-house while providing the flexibility to produce components with both in-autoclave and out-of-autoclave processes. Calspan’s experience composite technicians have the expertise to work with various materials and lay-up techniques.

Clean / Lay-up Room

  • 35’ x 50’
  • Independent temperature & humidity controls
  • Meets ASTM F25 particle-count requirements for a Class 10,000 (ISO 7) clean room

Autoclaves

  • 60” x 20’ Capacity 
  • 64” x 11’ Capacity
  • 500°F at 120 psi

Precision Machining

  • 3, 4, 5-axis CNC Milling and Turning Centers
  • High Speed CNC 5-axis Router: 144” x 60” x 48”
  • Milling: 48” x 96” x 240”
  • Turning: 74” Diameter

Freezers for composite material storage

Pre-Layup

  • Ply Cutting/Kitting for Hand Layup
  • Core Forming and Sculpting
  • Core Machining
  • Core Materials:
    • Aluminum & aramid fiber honeycombs
    • Rohacell PMI & polyurethane rigid foams
    • Balsa
    • Various specially treated honeycombs & foams

Paste Adhesives

  • Epoxies
  • Methacrylates
  • Urethanes
  • Ceramics

Fibers

  • Graphite (fabric & unidirectional)
  • Kevlar
  • Astroquartz
  • S2-glass
  • Fiberglass

Resins

  • Low temp cure epoxy:  RP1710, 828, 815, proset 125
  • Medium temp cure epoxy:  ACG GC329/LTM10 tooling pre-preg, cytec 7701 & 7714
  • High temp cure epoxy:  cytec 5270, 8552, 7661, CGL1310, ren4014, hexcel F155
  • BMI:  cytec 5250-4, hexcel F650 & F652 
  • Phenolic 

Film adhesives

  • FM 410, FM 300, HYSOL 9628, and hexcel MC7400 copper-filled epoxy film adhesives
  • Mb2550m bmi
  • Hp655 bmi

Calspan offers a full range of tooling capabilities, from low-cost wood and Ren shape to high-temperature composites and Invar. We conceive, design, fabricate and implement a variety of precision tooling for composite lay-up and curing. Our design engineers, manufacturing engineers and fabrication team work within an Integrated Product Team environment to optimize the tooling designs and fabrication processes.

Our tooling capabilities include:

    • Composite
    • Wood
    • Ren
    • Metal

  • ISO 9001:2015 registered
  • AS 9100D registered
  • NADCAP Accreditation – Composite Core Processing
  • ASQ Certified Quality Managers and Technicians
  • Climate controlled inspection laboratory
  • Fixed Coordinate Measuring Machines, Portable Arm Coordinate Measuring Machines,
  • Laser Tracking and Non-contact Laser scanning metrology equipment