Composites-By-Design LLC was founded by Michael Milauskas in 1998. Our initial product was a hybrid composite housing for a portable real-time 80Kv X-ray unit for use by US military and clandestine US agencies. Currently under design and prototyping is a line of consumer and commercial furniture fabricated from carbon fiber reinforced plastic (CFRP), and accented with exotic hardwood veneers.
The design intent is to create museum quality state-of-the-art CFRP furniture, without the outrageous prices demanded by others that work in this media. To do so, a proprietary vacuum assisted resin transfer molding (VARTM) was developed, requiring no autoclave or oven. In addition, various ultra-lightweight CFRP brackets are being developed for the serious photographer and videographer. A duel camera tripod mount is the first product being introduced.
Michael has been involved in the manufacture of advanced composites for aerospace since the early 1980’s. His first assignment was supervising the fabrication of boron/aluminum metal matrix composites used for the mid-fuselage struts of the U.S. Space Shuttle.
Mid-fuselage Structure of Space Shuttle Orbiter showing Boron-aluminum Tubes (photo credit: NASA)
Past Career Highlights
Project Engineer for Northrop-Grumman’s Counter-Man-Portable Air Defense CFRP Fairing (photo credit: NGC)
Process Engineer for the manufacture of NASA’s Super Lightweight Interchangeable Carrier (photo credit: NASA)
Materials Engineer for NAVAIR with oversight of the V-22 Composite Proprotor (photo credit: Wikipedia)
Boeing 787 Dreamliner Qualifications
In 2009, Michael completed a three year auditing assignment with Boeing Commercial Airplane (BCA) in the Technical Integration SQ Group. The audits were mandated to qualify the 787 Dreamliner advanced composite wing and fuselage structure at multiple BCA partner and supplier sites throughout Asia, Europe and the US.
The audits included KHI Section 43 Center Fuselage and KAL Section 48 Aft Fuselage to BAC5657, BAC5578 primary composite structure for FHI Section 11 Wing Box upper and lower panels and BAC5317 secondary composite laminates and Nomex cored structure for the 747-8 fairings and the 787 Wingtip. Audited processes also included hand layup, resin infusion and hot drape forming.
Founded One Other Corporation
US Army’s RC-7 Crazy Hawk Airborne Low M Reconnaissance Aircraft (photo credit: Aeronautic Pictures)
Flightline Composite Structures, Inc. (FCS) was created in the 1990’s to supply mission critical antenna coupler boots to all US Air Force F-15 Fighter Squadrons for the TEWS Electronic Warfare Program Upgrade. FCS also developed the component design structure, materials and processes for carbon/epoxy equipment racks and workstations, FLIR sensor doors, MTI radar mounts and wingtips for the US Army’s RC-7 Crazy Hawk Airborne Low M Reconnaissance Mission.
Mr. Milauskas resides in Piney Point on the Potomac River, southeast of Washington DC. He is an avid, but still learning, photographer and videographer, using Nikon SLRs and Sony mirrorless cameras with an interest in high dynamic range (HDR) photography. He enjoys kayaking and boating on the Potomac River, and is anxious to master his recently acquired DJI Phantom 4 Quadcopter. He travels frequently to Japan, Korea and Italy for design inspiration and exploration.