Complex Composites Manufacturing & Assembly

Your reliable source for quality complex composite part design, engineering, fabrication and assembly for a range of industrial and aerospace applications.

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Commercial Aerospace Composites
  • NADCAP certified
  • FAA repair station
  • EASA approved repair station
  • AS9100D
  • AS9110C
  • ISO9001
  • ASR
Composites For CH53K Helicopter

An Innovative Partner Delivering Reliable Complex Composite Parts

When you’re looking for a composite manufacturing supplier, you need a partner you trust to deliver consistent quality, innovative solutions and a competitive price. TIGHITCO has been providing build-to-print industrial and aerospace composite manufacturing services for customers around the world for more than 50 years.

  • Excellent Responsiveness
    TIGHITCO's team is excellent on responsiveness and working with their customers to ensure open items are resolved and parts are delivered. The program, sales, engineering, quality, and operations teams are always willing to work with us and ensure parts delivered in a timely manner.
    — Jason Abate, Sikorsky, a Lockheed Martin Company

Industries We Serve

  • Aerospace & Defense
  • Rotorcraft
  • Space
  • Energy
  • Industrial
Aerospace Military Composites Manufacturer

Complex Composites Manufacturing & Assembly Capabilities

Composites Fabrication & Assembly

  • Composite bonding
  • Metal bonding
  • Carbon fiber, Kevlar, fiberglass laminates
  • Honeycomb core, carbon fiber stiffeners
  • Grounding and lightning protection
  • Tooling design and manufacturing
  • Hand Layup
  • Laser Ply Projection
  • Automated ply cutting
  • Autoclave curing
  • Secondary bonding
  • Prime & paint
  • Composite repair
  • Major & complex composite assemblies & subassemblies
  • Composite and/or metal assemblies & subassemblies

Design & Engineering

  • Design assist and enhanced manufacturability
  • Composite engineering
  • Project development
  • Material selection
  • Computational fluid dynamics
  • Part modeling via CATIA V5
  • CATIA V5
  • UG NX7.5
  • MASTERCAM X4
  • 3dVIA, CPD
  • FIBERSIM
  • VERISURF
  • ENOVIA LCA

Non-Destructive Testing & Inspection Capabilities

  • Ultrasonic inspection
  • A and C Scan
  • In-house Level 3
  • Portable CMM
  • Field NDI available
  • Laboratory testing
  • Radiography (X-ray)
  • Liquid fluorescent penetrant
  • Eddy current
  • Magnetic particle
  • Borescope inspections to .6mm diameter
  • Thread gauge inspection
  • Hydraulic testing
  • CMM inspection
  • NADCAP certified FPI & MPI
Composites Manufacturing

Your Partner for Advanced Composites & Production

With decades of experience in composite aerostructure engineering, fabrication and assembly, TIGHITCO has the expertise and the equipment to develop solutions to your most challenging applications. Our expertise goes beyond the aviation industry to deliver quality complex composites for the industrial, space and energy sectors, among others. We have the capacity to handle large parts and our Six Sigma lean manufacturing processes help us deliver efficient, cost-effective composite manufacturing services for your application. You can count on us for rapid response and warranty-backed products with efficient post-production support. And with five locations across the U.S. and Mexico, we can deliver the most cost-effective production for your needs.

Our Composite Fabrication Equipment

  • 3 Layup Rooms (climate-controlled)
  • 4 High-temperature ovens (650°F, 6’x8’x6’)
  • 4 Autoclaves (high temperature and pressure)
  • Laser Projection System (precise ply positioning)
  • Non-destructive Inspection
  • Large 0°F Freezer (for sensitive materials)

Our Composite Engineering Process

Certification Support

  • Determine how each project will comply with regulations.
  • Review and adhere to relevant regulations.
  • Track internal audits to maintain process control.
  • Stay informed about industry regulations.
Composites Engineering Design

Composite Part Design

  • Design parts in CATIA software.
  • Create or identify tool surfaces as needed.
  • Design plies on the tool surface, considering the type of panel (laminate or sandwich).
  • Determine materials and specifications for each ply.
  • Analyze production methods to optimize material usage and identify splicing or darting points.
  • Create flattened patterns for efficient nesting.
  • Generate cross-sectional views for ply drop-offs or ramps.
  • Create ply tables based on the design in CATIA.
  • Develop laser programs to project ply locations during layup.

Manufacturing Planning

  • Define the order and requirements for stacking plies.
  • Define vacuum bag construction.
  • Detail curing instructions and requirements in the job traveler.
  • Include part marking and trimming instructions in the job traveler.
  • Outline quality inspection points in the job traveler.
  • Include all necessary parts, hardware, and tools in assembly planning.
  • Create visual guides for assembly.
  • List any additional documentation needed for assembly in the job traveler.

Aircraft Composite Repairs

Abrasions and punctures: Minor surface damage like scratches and dents.

Disbonding and delamination: Separation of skin from core, often caused by impact.

Water damage: Water seeping into cracks, potentially causing structural issues.

Fuel damage: Contamination from fuel, oil, or hydraulic fluid, often requiring material replacement.

Aircraft Composite Repair
Repair Aerospace Composites

Composite Repair Process

1. Disassemble, Clean, and Inspect:
Thoroughly assess the damage using visual inspection and specialized techniques like:

  • Non-destructive inspection (NDE)
  • Paint removal
  • Tap testing
  • Ultrasound

Follow OEM guidelines specific to the material, part, and brand.

2. Composite Repair and Overhaul:
Repair type depends on the severity and type of damage:

  • Nonstructural Repairs: Cosmetic fixes like adding filler, sanding, and repainting.
  • Semi-structural Repairs: Address more than cosmetic damage, involving core material removal and rebuilding with laminates.
  • Resin Injection Repairs: Temporary fix for delamination by injecting resin.
  • Structural Repairs: Extensive repairs to primary structural parts using methods like scarfing or stepping to restore original strength and stiffness.

3. Assemble and Test:
Reassemble components and conduct thorough inspections or tests per OEM criteria. Ensure proper curing, bonding, and absence of porosity or voids in the repair before returning the part.

Tell Us About Your Composite Component Needs
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