Radomes

As a structural, weatherproof enclosure, radomes are designed to protect antennas at subsonic and supersonic speeds with minimum interference to radar transmissions. Blade, low-profile, and ballistic radomes provide numerous advantages because composite materials are used when designing them. The advantages of these radomes are:

• Low dielectric properties (fibers and resins)

• Low Loss Tangent

• Increased stiffness with lower weight

• Special coatings

• Thermal stability

Royal Plastic Mfg., Inc. manufactures radomes out of composite material such as:

• E-Glass

• S-Glass

• Quartz

• Spectra Shield®

Typical resin systems that are used when creating radomes are:

• BMI

• Cyanate Ester

• Epoxy

Composite radomes at Royal Mfg., Inc. are designed to precise specifications and Royal will help select the appropriate radome for your application. 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.

Space Applications and Satellite Components

The parts shown above are examples of satellite receivers, transmitters, and shielding covers for satellite equipment. These parts are fabricated from quartz fiber reinforcement with a cyanate ester resin system.

Composites weight 32 percent less than aluminum and the fibers can be oriented to maximize performance allowing for a high strength to weight ratio. Copper circuits are embedded in the composite part to make a lightweight platform for space applications.

At Royal we have created S-band transmitters up to 4.50 feet in length. On the left, an S-band transmitter is shown that is 18.0” in length.

A housing unit for satellite optics is also shown. 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 stimulates spacecraft launch.

Additional Features:

• Composite structures provide improved strength and stiffness to weight performance versus conventional fabricated 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.

ECS Ducting

These ECS ducts are fabricated from Kevlar® and carbon fiber with an epoxy resin system. This allows for the utilization of an ultra low weight design for optimum performance.

In the center, the carbon fiber ducting shown incorporates a specialized design for military helicopter airframe platforms. Proprietary technology is utilized by this new ducting 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 0package features over 70 total parts with a combined weight of less than 17 lbs. These ducts consistently outperform a lengthy list of standard military specifications.

Specially insulated ECS ducts are fabricated from a polyester resin system with fiberglass reinforcement. The ducting system show above is designed for use in a restricted envelope environment, utilizing a low profile aerospace insulation. This provides 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.

Secondary Aircraft Structure

These secondary aircraft structures enclose radar equipment and are constructed of carbon fiber (graphite) with an epoxy resin system.  Designed to operate at up to 290° F, tolerance of +/-.005” are maintained. In the center is a flight surface door used to enclose and protect avionics equipment. One the left and right are leading edge fairing that meets stringent structural requirements. These fairing have been built to meet specific engineering requirements.  Specialized fasteners can be incorporated into any composite fairing design and many specialized coatings, such as hydrophobic or static dissipation coatings, and are available for demanding product applications. Also shown is a carbon fiber exterior access door for avionics. Numerous pieces of custom hardware were fabricated for this application with specialty coating applied to protect against corrosion, including static dissipation strips, locking quick release fasteners and high tolerance attachment hinges.

Composite Covers

Royal Plastic manufactures advanced composite covers for interior and exterior aircraft surfaces. Composite covers seal our moisture and contaminants, protecting sensitive equipment and providing easy access for maintenance when needed. Advanced composite covers can be designed with protecting 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.

 

Back to the top of the page...