Radomes are designed to protect antennas at subsonic to supersonic speeds
with minimum interference to radar transmission. Using advanced
composite materials when designing and manufacturing various types of
radomes such as blade, low-profile, and ballistic radomes provides numerous
advantages such as:
Low dielectric properties (fibers and resins)
Low loss tangent
Increased stiffness with lower weight
Special Coatings
Thermal Stability
Typical composite material used:
E-Glass
S-Glass
Quartz
Spectra Shield®
Typical resin systems used:
BMI
Cyanate Ester
Epoxy
Royal Plastic manufactures composite radomes to precise specifications
and can assist in selecting the appropriate radome for your application.
All radomes are designed using advanced composite materials that optimize
performance for the required application. Large radome designs feature
specially designed composite structure where applicable to enclose radar
units. The composite structure can be solid wall, multi-layer,
sandwich construction or even have reinforcing ribs. Small radomes
feature additional technology such as Rohacell® foam technology.
Radome design and construction can be tailored to minimize loss at specific
frequencies with optimum strength. Numerous topcoats are available
including epoxies, polyurethanes, fluoroelastomers, hydrophobic and
anti-static coatings. Specialized mounting hardware such as captive
fasteners and lightning diverter strips can also be supplied.
The above are examples of satellite receivers, transmitters and shielding
covers for satellite equipment.
Copper circuits are embedded in the composite part to make a light weight
platform for space applications. The above shown parts are fabricated
from quartz fiber reinforcement with a cyanate ester resin system.
These products are photographed before and after an elevated cure, which
enables these parts to have a 500° F service temperature.
Shown to the left is a S-Band transmitter that is 18.0" in length.
Royal has manufactured S-Band transmitters up to 4.50 feet in length.
Also shown above is a housing unit for satellite optics. This
particular example is extremely accurate and maintains surface and
positional requirements of +/- .005" throughout the entire part and has been
qualified through a 9G vibration test that simulates spacecraft launch.
Additional features for satellite components:
High strength to weight ratio - Composites weigh 32% less than
aluminum and the fibers can be orientated to maximize performance.
Composite structures also provide improved strength and stiffness to
weight performance versus conventional fabricated aluminum structures.
Radar Transparency - Various glass fibers and organic matrix are
relatively invisible to radar or microwave transmissions.
Durability - Composites provide high abrasion and impact resistance
while offering improved fatigue life.
Special Operations - High performance composites can operate under
extreme conditions, temperatures and pressures.
The above shown ECS ducts are
fabricated from Kevlar® and carbon fiber with an epoxy resin system,
utilizing a ultra low weight design for
optimum performance. The carbon fiber ducting shown above center,
incorporates a specialized design for military helicopter airframe
platforms. This new ducting utilizes proprietary technology to create
graphite fiber composite ducts capable of zero leakage performance and with
a wall thickness of only 0.013". Stringent requirements on internal air
flow temperature dictate the addition of low density, low thermal
conductivity insulation blankets on many of the ducts. This ultra low
weight design package featured over 70 total parts with a combined
weight of less than 17 lbs. These ducts consistently outperform a
lengthy list of standard military specifications.
The above shown are specially
insulated ECS ducts that are fabricated from a polyester resin system with
fiberglass reinforcement. This ducting system is designed for
use in a restricted envelope environment, utilizing a low profile aerospace
insulation for optimum performance.
This ducting package incorporates a specialized design for retrofit on
military surveillance platforms. These ducts are engineered to
consistently outperform standard military specifications.
The above shown secondary aircraft structures enclose
radar equipment and are constructed of
carbon fiber (graphite) with an epoxy resin
system. These aircraft fairing units
are designed to operate up to 290° F
temperature requirement. Tolerances of
+/- .005" are maintained. The
center example is an flight surface door to
enclose and protect avionics equipment. The
left and right
examples are leading edge fairings
that meet stringent structural requirements.
Royal Plastic transitioned these fairings to
meet specific engineering requirements and
performed full FEA analysis and composite
design engineering through full production. Specialized fasteners can be incorporated
into any composite fairing design.
Also many specialized coatings, such as
hydrophobic or static dissipation coatings
are available for demanding product
applications. Also shown is a carbon
fiber exterior access door for avionics.
Numerous pieces of custom hardware,
including static dissipation strips, locking
quick release fasteners and high tolerance
attachment hinges were fabricated for this
application with specialty coatings applied
to protect against corrosion.
Flexible composites can provide flexibility while maintaining strength
and durability. In addition flexible composites can meet or exceed FAA
flammability and smoke emission requirements while providing solutions to
unique applications. In most applications, ply's or layers of a
flexible elastomer or rubber are reinforced with an advanced composite cloth
to create a strong yet flexible product.
Available types of elastomers:
Silicone - FED STD ZZ-R-765 - Royal Plastics standard rubber.
Silicone weathers well and has low smoke emission in a fire.
Typical applications involve a service temperature up to 500° F.
Silicone is resistant to high and low temperatures and aliphatic
solvents, oils and greases.
Neoprene - Best resistance to aircraft fuel and oil, ozone,
sunlight, gasoline, aromatic or halogenated solvents. Easily
permeated by water. Typical application involves a medium range
service temperature with less stringent smoke emission requirements.
Nitrile - Good resilience, abrasion resistance and low heat build
up. Resistant to oils, hydraulic fluids and most hydrocarbons.
Typical application involves a medium range service temperature.
Fluorinated - Highest overall cost. Often used in specialty
applications. Chemical resistance is similar to silicone with
improved resistance to fuel, aromatic and chlorinated solvents.
Weakness with ketones and hydrazine.
Butyl - Good resistance to dilute mineral acid and alkali
concentrated acid, except nitric and sulfuric acid. Good ozone
resistance. Typical application involves a medium range service
temperature. Resistant to oils, hydraulic fluids and most
hydrocarbons.
Filament Winding is a major manufacturing process in the
fabrication of high performance polymeric composites, allowing the process
of filament winding to be the most efficient and least expensive method to
construct the basic infrastructure systems. Filament winding adds
material to a shape forming structure, using high strength to weight and
stiffness-to-weight properties that characterize continuous filaments of
advanced composite materials. By using filament wound processes
applications never corrode and remain maintenance free for decades,
competing in cost and performance with metallic structures. Filament
winding is a time-tested process that is not only versatile but continues to
be improved by use of information technology and mathematical analysis so
the precise and useful manufacturing and product design parameters are
provided to the engineers and managers who must make decisions relating to
cost and performance.
Continuous fiber reinforcement, provides the structural
performance required for the final part. The fiber is the primary
contributor to the stiffness and strength of the composite
Available continuous fiber reinforcements:
Fiberglass fiber
E-Glass - High strength (400-500 ksi), low modulus (10.5 msi),
lowest cost fiber, available in many forms, widely used in commercial
and industrial products
S-Glass - Improved strength (625-665 ksi), higher modulus (12.6 ksi),
higher cost fiber, used in aerospace and high performance pressure
vessel applications.
Carbon / Graphite Fiber - Increased performance, wide strength range
(270-1050 ksi), highest modulus (33-120 msi), highest fiber cost,
intermediate density, poor impact or damage tolerance, best tensile
strength and stiffness properties.
Thermoplastics - Including Spectra Shield
® with ballistic
properties
Aramid fiber - Good strength (450-550 ksi), higher modulus
(11.5-27.0 msi), higher cost fiber, very low density, excellent impact
and damage tolerance properties, poor compression and shear strength.
Kevlar®
The resin matrix provides the load transfer mechanism between the fibers
onto the structure. In addition to binding the composite structure together,
the resin matrix serves to provide the corrosion resistance, protects the
fibers from external damage, and contribute to the overall composite
toughness from surface impacts, cuts, abrasion, and rough handling. Resin
systems come in a variety of chemical families, each designed to provide
certain structural performance, cost, environmental, and/or environmental
resistance.
Available resins:
Polyester
General purpose polyester - Orthophthalic
polyesters, lowest cost systems, widely used in FRP industry,
moderate strength and corrosion resistance, room temperature cure.
Improved polyester - Isophthalic polyesters,
slightly higher cost, good strength and corrosion resistance, widely
used in FRP corrosion applications, room temperature cure.
Vinyl Ester - Chemical combination of epoxy and
polyester technology, excellent corrosion resistance, higher cost,
excellent strength and toughness properties, widely used as corrosion
liner in FRP products.
Bisphenol-A, Fumarate, Chlorendic - More exotic
systems for improved corrosion resistance in harsh environments, higher
cost resins, higher temperature capability, sees application in paper
and pulp industry applications.
Epoxy - Wide range of resins available, best strength
properties, usually heat-cure required, good chemical resistance, higher
viscosity systems, higher material cost, applications across broad
market segment range.
Royal Plastic can design and manufacture a lightweight, high performance
tubular structures for any application in the Aerospace, Medical, Oil and
Gas and Commercial Roller Markets. Specific technologies include; low TIR,
low inertia and high stiffness custom rollers, high torque drive shafts,
thick-walled flywheels and extreme pressure vessels.
The above shown filament wound application is an ultra high
pressure tube for use in a environmental testing facility. It is
constructed out of high-modulus graphite fibers with an epoxy resin system.
Wall thickness is .750". No liners are incorporated into this composite
tube design. This ultra high pressure tube has been tested to 22,000
ps.i. before failure. Also shown is an ultra high pressure vessel that
incorporates a metallic liner system rather than a standard thermal
insulation system used to contain the pressurizing medium.
Royal Plastic manufactures composite aircraft interior components to
precise specifications and can assist in selecting the appropriate design
for your application. All interior components are designed using
advanced composite materials that optimize for weight savings and
performance. Some interior components feature additional reinforcement
or localized metallic reinforcement to aid in increasing the structural
strength properties. Numerous topcoats are available including
standard matte finishes and anti glare coatings. Specialized mounting
hardware can also be supplied.
Royal Plastic manufactures a variety of rigid composite ducting utilized
on multiple aircraft platforms.
Advantages of rigid advanced composite ducting:
Diverse product applications for low-temperature, oven cure
polyester and epoxy ducts
Fire-resistant phenolic ducts for high performance applications
High-temperature autoclave cure cyanate ester or bismaleimide
ducting for operations in extreme temperature or pressure requirements.
Improved conformance to flame, smoke, or toxicity requirements
Durability and exceptional corrosion resistance
Rigid ducting can be used to supply cooling air to avionics or to remove
waste media from various aircraft components. Rigid composite ducting
can be designed to operate at a specifically required flow rate while
retaining necessary fit tolerances or clearance in restricted envelope
environments. Rigid composite ducting can also be supplied with or
without flexible cuffs to compensate for slight misalignment upon
installment in the aircraft.
Royal Plastic manufactures advanced composite covers for interior and
exterior aircraft surfaces. These cover seal out moisture and
contaminants, protecting sensitive equipment and providing easy access for
maintenance when needed. Advanced Composite covers can be designed
with protective finishes to further protect against premature weathering or
environmental damage. Specialty hardware such as captive fasteners,
cam-lock fasteners, safety cables, lanyards, and safety placards can also be
attached as required.
