Composites-By-Design LLC is an aerospace materials & process consulting firm established in 1998. We are available globally for short or long-term assignments to assist clients with new processor qualifications and work packages in the aerospace advanced composite markets. Over the years, we have contributed to all of the aircraft and spacecraft shown below.

The use of advanced composites, specifically carbon fiber reinforced plastic (CRFP), has skyrocketed since the introduction of the Boeing 787 Dreamliner and, more recently, the Airbus A350. These airframe integrators are perpetually seeking new suppliers to meet demand and reduce costs. We provide the services listed below at highly competitive rates.


Advanced Composite Supplier Qualifications to Boeing, Bell & Bombardier Process Specifications

We provide 1st & 2nd tier supplier support for Boeing, Bell and Bombardier advanced composite part qualifications including processor, equipment, preproduction verification and first part qualification. We have successfully walked several clients through the entire process from pre-audit to the completion of First Part Qualification. We will be on-site as needed during the initial phases and audit dates, and on call to assist in closing out action items to get your organization into production.

We have developed client templates for Facilities Operating Procedures, Equipment Qualifications, Thermal Profiles, PPV and FPQ Plans & Reports to meet the requirements of Boeing Commercial Airplane Company’s BAC 5578 and 5317.

Prototyping and Production Scale-up of Advanced Composites

As an IPT member for Northrop-Grumman’s Counter-Man-Portable Air Defense Composite Fairing, we had responsibility for all tooling, process development and planning for the composite pod assembly. We assured our client delivered one prototype and six flight articles over an aggressive 7-month schedule.

For the RC-7 Crazy Hawk Airborne Low M Reconnaissance Mission, we assisted our client in the design, certification and fabricated of carbon/epoxy equipment racks & workstations, FLIR sensor doors, MTI radar mounts and wingtip radomes.

Turnkey Project Management in Launching New Programs

We recently completed a project in 2015 supporting a major secondary structure work package for the Bell 525 Helicopter for a client in the Midwest. Previously we supported major aerospace manufacturer on two concurrent programs, from design low rate production: the Augusta/Westland AW189 and Bell 525 Main Rotor and Tail Rotor composite deicing systems. We also provided support for the manufacture of NASA’s Super Lightweight Interchangeable Carrier (SLIC) for the Hubble Service Mission 4.

Process Specifications Development

Under contract to Boeing Helicopter, we developed the principle D210 process specification for the CH-47F Chinook Block II Rotor Blade Program, a newly designed S2/CFRP blade offering 15% improved lift over legacy rotor blades. Previously, we completed a major revision to Gulfstream’s advanced composite process specifications with the objective to improve yields, reduce defects and simplify fabrication & inspection requirements.

Materials Qualifications

While on site at the Boeing Mesa Facility, we supported the M&P Group to develop test plans and complete two major advanced composite materials qualifications for the MD Explorer Helicopter Rotor Blade (Hexcel F584) and MD Series Tailboom/Empennage (Cytec 950-1).

Contact Us

Should your organization, large or small, need cost-effective assistance in launching a new program, or qualifying your  facility to any prime airframe integrator, please contract us at 301.994.2044.