Aerospace



Aerospace


Synthesites intelligent monitoring systems can provide valuable information about the manufacturing process readily offering the means for process optimisation, quality control and automation.


In the development stage, disposable and durable sensors can be easily introduced at various locations into the cavity to:

  1. Study the resin flow and its repeatability
  2. Optimise the filling scenario
  3. Calculate the permeability tensor necessary for accurate filling simulations especially for thick or complex components
  4. Record when resin entries and leaves the mould
  5. Check when the filling is done to start the heating ramp
  6. Check the viscosity rise to ensure the complete wet-out of the preforms
  7. Monitor the cure and optimise the temperature profile
  8. Optimise the cure profile
  9. Monitor and adjust the exotherm peak for thick structures
  10. Define process milestones using the sensors in order to use them at production

(bullets #6, #7, #8 and #9 refer also to the manufacturing with prepregs)

At certification stage, the use of Synthesites intelligent monitoring systems can:

  1. prove the process repeatability and part quality
  2. monitor several important processing parameters for processing traceability
  3. provide significant process parameters for quality control purposes

At production, the use of Synthesites intelligent monitoring systems can:

  1. Ensure that the quality of the resin (neat or in prepregs) meets the standards (mixing ratio or thermal ageing) before the start of the process
  2. Control the mould filling by opening and/or closing the appropriate inlet/outlet gates
  3. Check in real-time whether the resin flow pattern is as planned
  4. Check when the filling is over to start the heating ramp
  5. Check the viscosity rise to ensure that the injection time is adequate
  6. Check the viscosity drop during heating to apply pressure
  7. Monitor the cure and optimise the temperature profile
  8. Simulate in real-time and control the exotherm peak for thick structures
  9. Prove repeatability and provide online part quality certification
  10. Monitor many important parameters for process traceability
  11. Calculate process parameters for quality control purposes
  12. Adjust the optimised process cure cycle in real-time according to sensors’ feedback

(bullets #6 to #12 refer also to manufacturing with prepregs)