Aerospace Composites Division
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Overview

Helicopter Complex
Welcome to the Composites Manufacturing Division, Hindustan Aeronautics Limited  (Helicopter Complex) .

Brief History

Composites Manufacturing Division, the youngest outfit in this gigantic set-up was conceived, as early as the dates of design of Light Combat Aircraft (LCA) & Advanced Light Helicopter (ALH) and has over 15 years of experience in manufacturing and realizing aircraft structures made of composites. Over the years the scope and role of the facility was defined and refined from ‘Advanced Composites Shop’ to ‘Centre of Excellence’. The Division became fully functional from April 2007 as a Strategic Business Unit (SBU) of HAL.

Currently, the Division is manufacturing the composite structural parts for Advanced Light Helicopter (ALH), Light Combat Aircraft (LCA), Light Combat Helicopter (LCH), Light Utility Helicopter (LUH) and PSLV/GSLV.

In a major diversification initiative, the Division has developed capabilities to manufacture and export high precision Composite parts.

The Division is equipped with modern infrastructure in Plant and Equipments like Environmental Control Area of various Classes, -20degC Cold Stores, Autoclaves, High precision 5-Axis CNC Machining Centers, Automated Ply Cutting Machines, Surface Enhancement Machine (Shot Peening), Hot Platen Presses, Computer Controlled Air Circulating Ovens, Laser Projection Systems for Lay –up, CT-Scan, Ultrasonic C-Scan, Coordinate Measuring Machines, Laser Tracker, Universal Testing Machines and material test laboratory for composite material testing.

With average production rates of several thousand composite parts annually for many of our products, Composites Manufacturing Division is one of the top high volume producers of advanced composite aerospace products in the country.
The Division has the following High Tech. facilities:
  • CAD / CAM manufacture
  • CAD (Tool Design)
  • CATIA / UG (NX6) Work Stations
  • 5 Axis Special Purpose CNC Machining Centers
  • CNC Shot Peening (Surface Enhancement)
  • Programmable Prepreg Cutting Machines
  • Autoclaves (Max size is 4M(diameter) x8M(Length))
  • Computer Controlled Air Circulating Ovens
  • Hot Platen Presses
  • Environment Controlled Area (ECA) / Contamination Controlled Area (CCA)
  • Filament Winding Facility
  • - 20 deg C Cold Stores
  • Computed Tomography (CT-Scan)
  • Ultrasonic C-Scan
  • Universal Testing Machine (UTM)
  • Co-ordinate Measuring machine (CMM)
  • Digital Scanning Calorimeter(DSC)
  • Thermo Gravimetric  Analyzer (TGA)
  • Dynamic Mechanical Analyzer(DMA)
  • Laser Projection Systems for Lay-up
  • X-ray Fluoroscopy
  • Laser Tracker
What we can Offer
Airframe
  • Aircraft structural components made of advanced composite materials
     - Honeycomb sandwich bonded structures
     - Co-cured / Co-bonded components
  • Dynamic parts for Helicopters
     - Rotor systems (Main Rotor Blades, Tail Rotor Blades, Hub Plates and Torque plates etc.)
  • Helicopter structural assemblies (Doors & Cowlings)
Composites Manufacturing Division is exploring potential business opportunities with private partners for service and support for supply of composite & metallic toolings and metallic/ composite parts.

To support for composite parts and tooling, the exposure is expected to have in the following areas:
  • Exposure in design, development and fabrication of tools, manufacturing & supply of monolithic and sandwich composite parts.
  • Facilities such as Autoclave, Clean room, Cold storage, Core machining, Universal testing machine, Ultrasonic testing machines etc. for manufacturing for composite parts.
  • AS9100C certification for manufacturing and supplying of aerospace components.
  • Exposure in design and development of fixtures, checking templates, machining and supply of cured composite components, foam parts etc.
  • Exposure in NC programming and CNC machining of epoxy tooling boards of various shapes and sizes, metallic tooling predominantly of Aluminum alloys and tool steel etc. The machining of tools to be carried out on 3-axis or 5-axis machining centers.
  • Laser inspection services for tooling / jig setting using scanning and tracker, CMM inspection services etc.
  • NDT Facility.
For metallic parts the support is expected in the form of:
  • CNC and conventional machining facilities
  • CNC and conventional jig boring facilities
  • Wire cutting facility
  • Fabrication of sheet metal parts
  • Spline cutting facility
The Composites Manufacturing Division, Bangalore is an AS9100C and ISO 14001 : 2004 certified company. The Division holds NADCAP approval for Surface Enhancement (SE), Composites manufacturing, and NDT (UT) processes.
Products in Current Manufacturing Range
A. Composite components for Advanced Light Helicopter (ALH)
ALH
  • Hingeless Main Rotor Blade
  • Bearingless Tail Rotor Blade
  • Main Rotor Hub Plate
  • Anti Resonance Isolation System ( ARIS)
  • Torque Plate
  • Rescue Hoist Beam
  • Major structural components like Cockpit, Doors, TailBoom, EndPlate, Cowling etc.
B. Composite components for Light Combat Helicopter (LCH)
LCHThe LCH, a derivative of Advanced Light Helicopter, is a dedicated attack helicopter built to meet the requirements of armed roles for operations. The dynamic systems of the Dhruv have been adapted in it, making it both formidable and dependable.

The beauty has a narrow fuselage and tandom crew seat. Major structural and dynamic parts are made out of advanced composite materials.
C. Composite components for Light Combat Aircraft (LCA)
LCAComposites Manufacturing Division has successfully manufactured and produced state of the art Primary Structural Components for Tejas (LCA) using advanced composites materials. A few examples are control surfaces using co-cured construction, fuselage doors, hatches using sandwich and monolithic construction and large wing skin panels / airbrake skins. CMD has specialized in manufacture of Carbon fibre Composites (CFC) wing assembly details parts consisting of a number of CFC spars, monolithic skin panels etc.
D. Flexible Rubberized Fuel Tank for Advanced Light Helicopter (ALH)
ALHComposites Manufacturing Division is manufacturing the Flexible Rubberized Fuel Tanks for Advanced Light Helicopter (ALH).
E. Cowlings for Ecureuil helicopter-Eurocopter, France
Eurocopter, FranceComposites Manufacturing Division manufacture and export advanced composite cowlings for Ecureuil helicopter- Eurocopter, France.
Repairs, Major Servicing and Supply of Spares
As part of Customer service, Technical and Logistic support is provided. Technical support is rendered to the Customer in the following areas:
  • Maintenance and Repair of Composite assemblies
  • Compliance of Modification and Technical Instructions
  • Accident and Incident Investigations
  • Training of Customer's Personnel
On the Logistic side, the support is rendered in the following areas:
  • Supply of spares
  • Supply of items against priority demands like AOG
Customer’s operating personnel are provided training in servicing and maintenance of Parts manufactured by the Division through in-plant training courses, workshops and interactions at operating base.
Composites Manufacturing Division, has carried out
A. Manufacture of:
  • Monolithic & sandwich construction structural parts for ALH, LCH, LCA and Cowlings for Ecureuil helicopter, France.
  • Honeycomb Sandwich bonded structures, metal-to-metal bonded components.
  • Composite components in Carbon, Kevlar & glass Prepreg.
  • Dynamic components like Main Rotor Blade, Tail Rotor Blade, Hub plates, ARIS Spring. For ALH & LCH
  • Door Assembly for ALH & LCH
  • Co curing of composites parts
  • Machining of composites parts
B. Design and Manufacture of :
  • Composites Moulding Tools
  • Master Models for Tooling
C. Servicing of:
  • Transmission components
  • Structural components
Please contact:
General Manager
Composites Manufacturing Division
Helicopter Complex,
Hindustan Aeronautics Limited
Marathahalli Post,
Bangalore - 560 037, INDIA.

E-mail ID: gm.cmd@hal-india.com
Telephone: 91 - 80 – 22314764
Fax: 91 - 80 - 22315005
A. National
Director General of Aeronautical Quality Assurance (DGAQA), India.
Director General of Civil Aviation (DGCA), India.

B. International

Boeing Airplane Company, USA.
  • BAC 5730
  • NAS 410
Eurocopter, France
IAI , Israel
NADCAP (AC7117/2, AC7114 & AC7118)