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Composite Structures Design & Analysis

We Offer

Design, analysis and manufacturing support for composite structures and components across a range of sectors.

Experience

Decades of experience in designing composite structures for many applications, from satellites to submarines.

Relationships

Close relationships with composite manufacturers and test houses, with access to a vast database of composite material properties.

Our Capabilities

Design
  • Concepting, detail design & drawings
  • Materials selection & laminate design
  • Environmental protection
  • Thick & thin composite structures
  • Cored composite structures
  • Tooling design
  • Manufacturing specifications
Analysis
  • Laminate analysis and synthesis
  • Structural optimisation
  • Combined multi-material assessments
  • Adhesive bonding analysis
  • Dynamic & non-linear analysis
  • Filament winding analysis
  • Ply failure assessments
Testing
  • Vast database of tested material properties
  • Selecting appropriate coupon tests
  • Understanding of testing standards
  • Writing qualification documents
  • Selecting number of tests (A or B basis)
  • Sub and full component testing specification

Client Cases

Composite Aero-Engine Intake

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We designed a composite intake for aero-engine crosswind testing. To allow for Particle Image Velocimetry (PIV) of the airflow, sections of the intake were replaced with cast acrylic windows, posing challenges for weight, structural integrity, and dynamic response requirements. Our efficient design and analysis optimisation methods allowed us to efficiently iterate the design, altering the composite lay-up in strategic areas to remove weight whilst maintaining strength and stiffness. Our ability to efficiently analyse multi-material structures was vital in the successful delivery of a solution to the demanding customer requirements.

Filament Wound Pressure Vessel

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Our team used combined composite design and analysis capabilities to optimise a high-pressure carbon-wrapped hydrogen fuel tank, to be used in a hydrogen fuel cell vehicle. Initially we used synthesised layup models for fast design iteration and optimisation, followed by full 3D composite wound mesh models for final structural assurance. To create these 3D models we have developed unique in-house software tools which allow us to translate between CAD/CAM robotic filament winding software, and our own structural analysis software. This capability allows us to assess different filament-wound designs swiftly and accurately.

Composite Aero-Engine Intake

We designed a composite intake for aero-engine crosswind testing. To allow for Particle Image Velocimetry (PIV) of the airflow, sections of the intake were replaced with cast acrylic windows, posing challenges for weight, structural integrity, and dynamic response requirements. Our efficient design and analysis optimisation methods allowed us to efficiently iterate the design, altering the composite lay-up in strategic areas to remove weight whilst maintaining strength and stiffness. Our ability to efficiently analyse multi-material structures was vital in the successful delivery of a solution to the demanding customer requirements.

Filament Wound pressure Vessel

Our team used combined composite design and analysis capabilities to optimise a high-pressure carbon-wrapped hydrogen fuel tank, to be used in a hydrogen fuel cell vehicle. Initially we used synthesised layup models for fast design iteration and optimisation, followed by full 3D composite wound mesh models for final structural assurance. To create these 3D models we have developed unique in-house software tools which allow us to translate between CAD/CAM robotic filament winding software, and our own structural analysis software. This capability allows us to assess different filament-wound designs swiftly and accurately.

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