Somerset West-based aircraft and automotive components manufacturer AAT Composites is increasing its reach into the aerospace components industry by producing specialist parts that are lighter and less costly than conventional metal or plastic parts.

These parts vary in size and configuration, from cockpit interior panels to aircraft and helicopter seats and support infrastructure, and even external aircraft panels.

AAT Composites innovation and portfolio senior manager Dr Louis Tredoux says the company was awarded a contract in February to develop tooling and to manufacture various parts for aircraft manufacturer Pilatus. The parts are destined to be installed into the Pilatus PC-12 passenger aircraft. The contract consists of four different work packages, including the manufacture of large (some as big as 4.5 m long) interior composite components and exterior aircraft panels. “In total, we will be supplying Pilatus with about 80 different parts,” he says.

AAT Composites also manufactures economy- and business-class seating components, such as backrests, privacy surround panels, armrests and tray tables, for various commercial flight operators.

In terms of trends in the composites industry, Tredoux highlights that constant innovation is required to ensure that the latest products being manufactured feature enhanced weight reduction with higher levels of strength and stiffness to meet the demanding working environment in the aerospace industry.

However, the cost of producing lightweight and strong composites is a challenge because of the intricate manner in which composites are pieced together, which requires the facilitation of various materials to be incorporated into the composite while it is being made. This requires innovation to improve manufacturing methods, especially in terms of reducing energy when producing products.

Another key area for improvement is the acceleration of cycle times for making a number of parts. In this regard, the company has implemented a new thermoplastic press that reduces cycle times to between five and ten minutes, compared with the usual times of 90 to 120 minutes.