Today we’ll be demonstrating the manufacturing process for the carbon fiber, upper and lower fuselage for the Zone 5 CLEAVER, a Cargo Launch Expendable Air Vehicle with Extended Range platform. We will be showing the fabrication using the Hawthorn Composites Advantage that includes dry fiber fabrics and vacuum assisted resin transfer molding (VARTM) with low-cost infusion grade epoxy resin. We …

PROBLEM Develop and fabricate a rate compatible manufacturing solution for Zone 5 Technologies, LLC to build the complex geometry, carbon fiber composite fuselage for its CLEAVER (Cargo Launch Expendable Air Vehicle with Extended Range) platform. OPPORTUNITY Create a solution to manufacture this complex geometry, composite fuselage, focusing on dry carbon fiber and epoxy resin infusion with novel manufacturing methods, to …

Spintech Holdings has now been in our new headquarters for nearly three years and we have added significantly to our talent, capabilities and overall efficiency. Please take a look at our updated facility tour showing off some our newest additions that enhance our ability to deliver high-value, complex geometry composite parts through our Hawthorn Composites division.   Automated Fabric Cutting …

Today we’ll be demonstrating the advantages of fabricating a foil and strut for the ORPC RivGen® Power System. We will be showing the fabrication of a foil using the Hawthorn Composites Advantage that includes using custom, dry carbon fiber and resin transfer molding (RTM) with industrial grade epoxy resin. First the carbon fabric is cut to precise ply shapes using …

RE-ENGINEERING THE COMPOSITE PARTS Through collaboration with ORPC and our partner, A&P Technology (A&P), we re-engineered the ORPC foil and strut to achieve the same structural results of the composite parts made by hand lay-up of pre-preg according to a detailed ply schedule with an autoclave cure to a custom braided, dry fiber ply schedule, combined with resin transfer molding …

11/1/2020 – Updated 7/21/2023 (Dayton – OH) Hawthorn Composites, the Dayton-based manufacturer of high-performance structural composites, was awarded a structural inlet duct manufacturing contract from Kratos Defense & Security Solutions, Inc. to provide twelve inlet ducts for the XQ-58A Valkyrie platform. The twelve structural inlet ducts will be made using Smart Tooling’s shape memory polymer (SMP) tooling, combined with overbraiding …

PROBLEM How to fabricate a composite fiber shaft in the US eliminating supply chain logistic and lead time issues while meeting targeted cost range. OPPORTUNITY Deliver a solution using a combination of high levels of automation with lower cost materials and manufacturing methods. SOLUTION Used automated fiber preforms, lower cost epoxy resins, and resin transfer molding (RTM) to make high …

To start, we designed the mold to be compatible with resin transfer molding and to meet the customers geometric requirements. Using automation to drive down labor costs, we use our 20′ cutting table to accurately cut fabric following the unique ply kit pattern for processing repeatability. First, a thick chopped strand fiberglass mat is cut in both large and small …

SWITCHING FROM METAL The previous enclosure door was fabricated using metal, resulting in an overweight door that caused a tipping issue when the machine was being restocked and required additional counterbalance for safe operation. This made moving the machine difficult so an lighter weight alternative was sought. CONVERTED COMPOSITE ENCLOSURE The customer required a composite solution that was a direct …

Watch a demonstration of how Hawthorn Composites can create a co-cured wing structure using a combination of dry carbon fiber, braided sleevings, liquid infusion, and Smart Tools. Hawthorn Composites delivers high value complex composites by deploying low cost materials with liquid infusion and novel manufacturing methods. This combination significantly lowers labor and material costs while maintaining structural integrity and weight …