Composites
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 having 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, 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 is going to manufacture and export high precision Aircraft Composite parts for Boeing 777 Commercial Aircraft & Boeing P-8I Military Aircraft. Division is currently manufacturing and exporting Cowlings for Eurocopter, France.

The Division is equipped with modern infrastructure in Plant and Equipment 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, 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.
Facilities
 The Division has High Tech facilities under the following major heads
  • 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 Mechanical Analyzer (TMA)
  • Dynamic Mechanical Analyzer(DMA)
  • Laser Projection Systems
  • X-ray Fluoroscopy
  • Laser Tracker
Accreditation
The Composites Manufacturing Division, Bangalore is an AS9100B and ISO 14001 : 2004 certified company. The Division also has Quality System and authorization to perform special processes from International Aerospace Companies such as Boeing, Eurocopter for export of precision aircraft composite components and assemblies. Division holds NADCAP approval for Surface Enhancement (SE) process.
List of Approvals
  1. National
    • Director General of Aeronautical Quality Assurance (DGAQA), India.
    • Director General of Civil Aviation (DGCA), India.
  2. International
    • Boeing Airplane Company, USA.
      • BAC 5730
      • BAC 5317-2,-3, & -4
      • BAC 5980 and NAS 410
    • Eurocopter, France
      • IAI , Israel
      • NADCAP (AC7117/2)
Products
Products in Current Manufacturing Range

Composite components for Advanced Light Helicopter (ALH)
  • Hinge less Main Rotor Blade
  • Bearing less 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.

Composite components for Light Combat Helicopter (LCH)

The 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.

Composite components for Light Combat Aircraft (LCA)

Composites 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.

 Composites Manufacturing Division is manufacturing the Flexible Rubberized Fuel Tanks for Advanced Light Helicopter (ALH).

Cowlings for Ecureuil helicopter - Eurocopter, France

Composites Manufacturing Division manufacture and export advanced composite cowlings for Ecureuil helicopter- Eurocopter, France.

International Co Operation
  • Composites manufacturing divisions is an established exporter to
    • Eurocopter - France
  • Composites manufacturing division has bagged firm order of export to 
    • Boeing - USA
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)
Services
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 InvestigationsTraining 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:
  1. 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
  2. Design and Manufacture of :
    • Composites Molding Tools
    • Master Models for Tooling
  3. Servicing of:
    • Transmission components
    • Structural components
Outsourcing
Composites Manufacturing Division is exploring potential business opportunity with private partners for service and support in supply of composite & metallic tooling and metallic/ composite parts.
For composite parts and tooling the support will be in the form of:
  • 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.
For metallic parts the support will be 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 faclility
Contact Us
General Manager
Composites Manufacturing Division

Helicopter Complex,
Hindustan Aeronautics Limited
Marathalli Post,
Bangalore - 560 037,
India.

Telephone: +91 - 80 - 22319000
Fax:            +91 - 80 - 22315005