Hawthorn Composites “Delivers high value, complex composites”. Today we’ll be demonstrating the fabrication of a carbon fiber,  Sub-section Trailing Edge control surface with acute internal cavity geometry. Hawthorn Composites will be utilizing Smart Tools to make the two cavities and the shear web of the sub-section control surface and incorporate a floating lid mold to ensure consolidation of the solid …

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 fuselage for its CLEAVER (Cargo Launch Expendable Air Vehicle with Extended Range) platform. OPPORTUNITY Create a fuselage composite solution to manufacture this complex geometry, 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 RTM infusion 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 …

RE-ENGINEERING THE COMPOSITE PARTS Through collaboration with ORPC and our partner, A&P Technology (A&P), we re-engineered the ORPC composite 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 …

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 …

COMPOSITE SHAFT 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 …

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 …