AeroStructures

Fully integrated, and able to quickly move through analysis, tooling, and fabrication

Aerospace

Rotorcraft

Defense

New Applications

Since 1972, TIGHITCO has been a leader in the aerospace and defense industry. With a prime focus on advanced composite structures, TIGHITCO has developed a reputation as a key player in the industry. Our meticulous craftsmanship enables us to achieve the high quality that the aerospace industry demands. We provide full lifecycle support of our products from conceptual design development, to testing and first part qualification/certification.

Being fully integrated, and able to quickly move through analysis, tooling, and fabrication, we will make any project an easy transition from a build-to-print or open design to a quality part. We offer a full-service solution; maintaining the unique ability to incorporate our engineering expertise and manufacturing talent to rapidly produce new products for our defense and commercial customers.

Advanced Composite Structures

Production Composites

By managing a “cell manufacturing” method similar to assembly line factories, TIGHITCO is able to realize very high-quality production efforts with a relatively small team of skilled technicians. Under the ISO 9001:2015 and AS9100D QMS, TIGHITCO maintains extremely low loss rate after nearly five decades of manufacturing.

Advanced Composites

TIGHITCO has a long history of producing advanced composite structures. We can offer the following services, equipment, and facilities for our advanced composite customers:

  • Layup Rooms: two isolated and fully climate-controlled rooms for composite layup
  • Ovens: two high temperature (up to 650° F), 6ft. x 8ft. x 16ft. curing ovens
  • Autoclaves: Access to three autoclaves for products that require high temperature plus high-pressure cure cycles
  • Laser Projection System: Extremely precise composite ply positioning
  • Non-destructive Inspection: testing via Thermographic cameras and Ultrasonic instruments
  • Freezer: Large 0° F freezer for storage of sensitive composite materials

Composite Engineering Process

Certification Support

  • Determine method of compliance
  • Review applicable regulatory requirements
  • Track internal audits to ensure process control
  • Maintain a good working knowledge of regulations with an experienced quality and certifications managers on staff

Composite Part Design

  • Parts created inside of CATIA. Tool Surface identified or created as required.
  • Plies designed on the tool surface for laminates. For sandwich panels, multiple surfaces are defined to account for honeycomb core
  • Materials and parameters are identified for each ply.
  • Producibility is performed for each ply to determine splicing or darting locations
  • Flattened patterns are created and used to create nests for optimal material usage
  • Cross sectional views are created for ply drop off or ramps
  • Ply tables are created from ply stack up defined in CATIA
  • Laser programs developed from 3D geometry to project ply location on the layup tool

Manufacturing Planning

  • Planning defines ply stacking sequences and requirements
  • Vacuum bag construction defined
  • Cure recipe and requirements defined in the job traveler
  • Part Marking requirements defined in the job traveler
  • Trim program and requirements defined in the job traveler
  • All quality inspection points defined in the job traveler
  • Assembly planning includes all detail parts required for fabrication, as well as any hardware and any special tools required.
  • Reference documents are created that show how the assembly is put together.
  • Job traveler details any other documentation required to complete assembly.

Benefits of Composites

Light Weight

Lighter than aluminum and steel, you can save weight or move them around easier.

Strong and stiff

With strength that’s comparable or superior to steel and aluminum, composites consistently outperform plastics.

Cost Efficient

Our composites are delivered shape and specification ready.

Thermally Efficient

Composites are excellent insulators and retain their shape in extremely hot or cold conditions.

Environmentally Durable

Unaffected by salty or acidic conditions, our composites are corrosion and chemical-resistant.

Electromagnetic transparency

Fiberglass has lower signal attenuation helping to keep data connectivity where it’s needed.

Centers of Excellence

Berlin, CT

Design, development and production of complex carbon composite aircraft structures

AeroStructures Division engineering and fabrication. Complex composite structures and assemblies, autoclave, bonded panels, captive phosphoric acid anodizing capabilities, sheet metal components and assemblies and light machining.

CERTIFICATIONS

NADCAP

ISO, AS9100 AND AS9110

Capabilities
  • Engineering & Design:
    • CATIA V5
    • UG NX7.5
    • MASTERCAM X4
    • 3dVIA
    • CPD
    • FIBERSIM
    • VERISURF
    • ENOVIA LCA
  • Composite Fabrication
  • Hand Layup / Laser Ply Projection
  • Major & Complex Composite Assemblies
  • Automated Ply Cutting
  • Sheet Metal Fabrication
  • Heat Treating
  • In-house Phosphoric Acid Anodizing
  • Metal Bonding
  • Laboratory Testing
  • Autoclave Curing
    • 7’-0” Diameter x 14’-0”
    • 8’-6” Diameter x 20’-0”
  • CNC 5-Axis Routing
  • CNC 3-Axis Routing
  • Prime and Paint
  • Portable CMM Inspection
  • Program Management
  • Tool Design
  • Tool Fabrication

Honeycomb Core Fabrication

Charleston, SC

Advanced Composites Manufacturing and Assembly Center

AeroStructures Division engineering and fabrication. Complex composite structures and assemblies, autoclave, bonded panels, and light machining.

 

CERTIFICATIONS

NADCAP

ISO, AS9100 AND AS9110

Capabilities
  • Engineering & Design:
    • CATIA V5
    • UG NX7.5
    • MASTERCAM X4
    • 3dVIA
    • CPD
    • FIBERSIM
    • VERISURF
    • ENOVIA LCA
  • Composite Fabrication
  • Hand Layup / Laser Ply Projection
  • Major & Complex Composite Assemblies
  • Automated Ply Cutting
  • Autoclave Curing
  • 9‘ Diameter x 30’
    • 12’ Diameter x 30’
    •   3’ Diameter x 5’
  • Ultrasonic Inspection (Dual Robot TT)
  • Prime & Paint

Program Management

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