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VCI OSC Aerospace Program
Large Primary Structure
6262”” Diameter Bisector Shell Payload FairingDiameter Bisector Shell Payload Fairing
Taurus Launch VehicleTaurus Launch Vehicle
Summary
– VCI has the capability to take your composite project from concept to reality and into high volume production.
– Over 30 years of experience prove that VCI is a well-established supplier to the composites industry.
Taurus Payload Fairing expanded view.
http://www.orbital.com/NewsInfo/Publications/taurus-user-guide.pdf
Nosecap
Payload Fairing
Payload Cone/Motor Support
Avionics Shelf (Aluminum laminate)
Avionics Skirt
Boat Tail
VCI makes these components’ composite structures:
Flight Stages Illustrated
http://www.orbital.com/NewsInfo/Publications/taurus-user-guide.pdf
We use CAD programs to design fabric plys and a CNC cutting table
to cut the flat patterns.
The Carbon fiber material is soaked with uncured epoxy resin.
Fabric plys are layered onto the tool. Core materials are layered on
top of the fabric.
After Lay-up, the tool and part are bagged for the Autoclave.
The vacuum bag allows the autoclave pressure to act on the laminate.
Parts are rolled into the autoclave for cure.
Autoclave Curing
The Autoclave is a Pressure Cooker
• The autoclave is a large pressurized vessel with environmental control.
• Parts are loaded with ports to the inside of a vacuum bag.
• Typically, vacuum is applied to a part at the beginning of a cycle.
• Once the vessel is sealed, temperature and pressure are varied as needed based on a “recipe.”
• The pressure differential between the inside of a bag and the pressure vessel creates significant compacting force on the part.
• Epoxy resins cure at elevated temperature to form the part to the shape of the mold tool.
Payload Fairing getting core put on.
Payload Fairing ½ way done.
Layup complete, into autoclave.
Andy sets up the instrumentation and controls
Door sealed and ready to start cure.
Fairing out of autoclave and bagging materials removed.
Halves mated with flange.
Jamel checks our handy work
The VCI and OSC Taurus structure team.
Following are some random images of the Taurus components
at VCI
Payload Cone after core.
Payload Cone and tool de-molded.
Payload Cone and Motor Support bonding and completed.
Avionics Skirt and Boat-tail
Boat-tail completed
OSC’s Brett checks the Fairing.
Nose Cap de-molded
Rate Sensor Shroud
OSC Apres’
Avionics shelf required CAD programming for many insert
locations.
Vermont Composites, Inc.Vermont Composites, Inc.25 Performance Drive25 Performance DriveBennington, VT 05201Bennington, VT 05201
(802) 442 (802) 442 –– [email protected]@vtcomposites.com
Company Overview
VCI Markets
VCI serves 2 primary market segments– Aerospace
• Military• Commercial
– Medical
We have provided advanced composites solutions for over 30 years
VCI Primary Customers
VCI Capabilities
Vermont Composites offers a full range of services from Conceptual Design to
High Volume Production
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
VCI EquipmentCurrent equipment list:
– Autoclaves• 8ft x 35ft, 150 psi, 450 deg F • 4ft x 8ft, 150 psi, 450 deg F
– Vacuum ovens• (4) walk-in models - 450 deg F• (1) 600 deg F
– Press• Double platen 150 ton, 600 degF
– Automated ply cutting table– Laser ply locating system– Clean room
VCI Materials Experience– Fibers
• Carbon fiber (standard, intermediate and high modulus, PAN and Pitch)• Glass (fiberglass)• Aramid (heat resistant)• Quartz (low dielectric strength, high temperature)
– Resin Systems• Epoxy• Phenolic• Cyanate ester (high Tg)
– Cores• Nomex honeycomb (aramid)• Foam (Rohacell)• Aluminum honeycomb• Syntactic (Syncore)
Aerospace Program ExperienceAerospace Program Experience
VCI Aerospace Programs
MHMH--60R 60R RadomesRadomes
Forward KuForward Ku--Band Band RadomeRadome
MMR MMR RadomeRadome Aft KuAft Ku--Band Band RadomeRadome
VCI Aerospace ProgramsC-130 DIRCM Support Structure and Fairings
Over 200 ship sets delivered to dateOver 200 ship sets delivered to date
VCI Aerospace Programs737 AEW&C Contract
Turkish PeaceEagle 737
Operator Work ConsolesOperator Work Consoles
Shielded EnclosuresShielded Enclosures
VCI Aerospace ProgramsC-130 Compass Call
Reconnaissance PodReconnaissance PodHeat exchanger Heat exchanger Panel Array Panel Array RadomeRadomeNose/Tail ConesNose/Tail Cones
Heat Exchanger
Panel Array
VCI Aerospace ProgramsCV-22 Osprey
VCI is producing several forward lower RAS panelsVCI is producing several forward lower RAS panelsleft & rightleft & right
left & right
VCI Aerospace ProgramsRQ-4 Global Hawk
Radar Processor ChassisRadar Processor Chassis
VCI Aerospace ProgramsP8-A PoseidonProduction per ship-set:
Tactical workstation Power equipment racks Oxygen enclosure
Oxygen EnclosurePower Equipment Racks (2)
Tactical Workstations (5)
VCI Aerospace ProgramsSpecialty Structures – low CTE components
FLIR Calibration System FLIR Calibration System -- AthermalAthermal CollimatorCollimator
VCI Aerospace ProgramsSpecialty Lightweight Enclosures
FLIR / Laser Alignment System EnclosureFLIR / Laser Alignment System Enclosure
VCI Aerospace ProgramsShielded Electronic Enclosures
RCRC--135 Rivet Joint 135 Rivet Joint -- Operator Console and Equipment RackOperator Console and Equipment Rack
VCI Aerospace ProgramsPrimary Structures
Pegasus Launch Vehicle Pegasus Launch Vehicle -- Composite Avionics Bay and Composite Avionics Bay and InterstageInterstage
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Conceptual DesignConceptual Design
•• Detailed DesignDetailed Design
•• CAD UtilizationCAD Utilization
•• SolidWorksSolidWorks®®
•• CATIACATIA ®®
•• UnigraphicsUnigraphics®®
•• Industry Standard Translation Industry Standard Translation
•• SurfCAMSurfCAM®® CNC ProgrammingCNC Programming
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Classical Theory Classical Theory –– Closed FormClosed Form
•• Finite Element Finite Element
••AbaqusAbaqus®® & Cosmos M& Cosmos M®®
•• StructuralStructural
•• VibrationalVibrational
•• ThermalThermal
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Composite LaminateComposite Laminate
•• Master ShapeMaster Shape
•• Prepreg MoldPrepreg Mold
•• Support StructureSupport Structure
•• MetallicMetallic
•• CNC MachinedCNC Machined
•• Sheet and FormerSheet and Former
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Fabrication ProcessesFabrication Processes
•• Hand LayupHand Layup
•• Autoclave / OvenAutoclave / Oven
•• Trapped BladderTrapped Bladder
•• Press MoldingPress Molding
•• StructuresStructures
•• MonolithicMonolithic
•• CoredCored
•• Stiffened (hat, grid, etc)Stiffened (hat, grid, etc)
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• CNC MachiningCNC Machining
•• 3,4 & 5 Axis 3,4 & 5 Axis
••Composites and Metal Composites and Metal
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Secondary BondingSecondary Bonding
•• Potting / Edge FillingPotting / Edge Filling
•• Mechanical AssyMechanical Assy
•• Hardware InstallationHardware Installation
•• Electrical BondingElectrical Bonding
•• CablingCabling
•• Component AssyComponent Assy
•• PaintingPainting
•• PrimePrime
•• TopcoatTopcoat
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• NDINDI
•• Ultrasonic Ultrasonic ““AA”” ScanScan
•• BondlineBondline
•• XX--RayRay
•• DimensionalDimensional
•• 3 Axis CMM3 Axis CMM
•• FARO Arm FARO Arm CMMsCMMs
•• Standard DimensionalStandard Dimensional
Measurement ToolsMeasurement Tools
VCI Capabilities
Our core competencies include:– Design– Analysis– Tooling– Fabrication– Assembly– Inspection– Testing
•• Coupon TestingCoupon Testing
•• Standard MechanicalStandard Mechanical
•• Component TestingComponent Testing
•• Static MechanicalStatic Mechanical
•• Proof LoadingProof Loading
•• Contract House ManagementContract House Management
•• EMI / RFIEMI / RFI
•• VibrationalVibrational
•• EnvironmentalEnvironmental
Contact Information
John KimballNew Business Development
[email protected] x1258
For further information, please contact:
Bill BergBill BergSr. VP Sr. VP –– Aerospace & DefenseAerospace & Defense
[email protected]@vtcomposites.com802802--442442--9964 x12459964 x1245
