Composite Manufacturing

Often there are several composite techniques which will successfully create the desired end product, only with experience and an extensive skill set can the proper technique be applied to the task at hand. Our customers draw upon more than a decade of experience in Cingularity TEC ability to select the correct manufacturing discipline for each program.

Advance Structures

The majority of today's complex composite structures require post cure machining of features and hole locations. We have developed a unique system for molding in simple and complex features into the product at the time of lay-up. Some products feature over 200 integrated features that require no secondary operations. These net cured composites can feature molded-in holes, slots, hardware, SLS components, antennas, and electronics. The elimination of secondary operations improves manufacturing consistency and reduces unit costs.

Composite Tooling

Invar tools, such as these massive wingskin tools shown here, exemplify the most durable of metal tools — a category sometimes called hard tooling. Although relatively heavy and expensive, metal molds are able to withstand many thousands of production cycles. Made of high-performance steel-and-nickel alloys, Invar and other metal molds are durable tool materials but also expensive and, because few composites manufacturers have the equipment necessary to machine and polish such materials, they often require the services of a toolmaking specialist. 

Composite parts are formed in molds, also known as tools. Tools can be made from virtually any material. For parts that will be produced in low quantities and can be cured at ambient or low temperature, or for prototype parts, where tight control of dimensional accuracy isn’t of prime importance, materials such as fiberglass, high-density foams, machinable epoxy boards or even clay or wood/plaster models often are suitable. Additively manufactured or 3D-printed tools, using polymers, are also becoming more common for both prototype and production parts. Tooling costs and complexity, however, increase as the requirements for part performance and/or finished surface aesthetics become more exacting and the number of parts to be produced increase. High-rate production tools, for example, are generally made of robust metals that can stand up to repeated cycles and maintain good surface finish and dimensional accuracy. The molds in which high-performance composite parts are formed can be made from carbon fiber/epoxy, monolithic graphite, castable graphite, ceramics or metals (typically aluminum, steel and alloys of the same). In all cases, each material offers unique capabilities and drawbacks.

Sometimes called hard tooling, metal tools, although relatively heavy and expensive, are able to withstand many thousands of production cycles. The most durable, but also most costly, are made of high-performance steel-and-nickel alloys, such as Invar. Because few composites manufacturers have the equipment necessary to machine and polish metal tools — particularly Invar — they often require the services of a toolmaking specialist.

Infusion VARTM

Vacuum Assisted Resin Transfer Molding (VARTM) or Vacuum Injected Molding (VIM) is a closed mold, out of autoclave (OOA) . Composite manufacturing process. VARTM is a variation of Resin Transfer Molding (RTM) with its distinguishing characteristic being the replacement of the top portion of a mold tool with a vacuum bag and the use of a vacuum to assist in resin flow.[ The process involves the use of a vacuum to facilitate resin flow into a fiber layup contained within a mold tool covered by a vacuum bag. After the impregnation occurs the composite part is allowed to cure at room temperature with an optional post cure sometimes carried out.

This process offers the benefit of not requiring an expensive autoclave while also being capable of producing large, complex aerospace-grade parts.

Defense Structures

Our wealth of experience with composites and polymers makes us perfect for supplying lightweight components for defence, increasing efficiency and protection. You get a complete manufacturing service, from tooling through to final assembly and paint finishing. Whether it is a vehicle hood, submarine mast or lightweight armour protection panels, we can provide a manufacturing solution.

With us, you get the best design and manufacturing support available plus rapid prototyping and series manufacture. With our climate-controlled clean rooms, autoclaves and injection mold machines, we have a manufacturing process to suit your needs.

We supply first class CNC machined aluminum and composite parts. With our range of CNC milling machines comprising the latest 3 & 5 axis technologies, and with our largest 3-axis machine up to 3m x 2m x 1m operating 24/7, we provide fast and comprehensive machining solutions to our defence customers.

Our facilities operate around the clock with quality control supervision and performance monitoring to ensure dependable and fast delivery of prototypes and series production while maintaining the highest quality.

Machining Capabilities

Composite Machining. Your partner in composite. contact us for a tailored solution. We strive to assist our customers with their needs in the composite manufacturing industry.

Infrastructure - Tool Room Machine Facilities

Cingularity offers a full-service manufacturing process for parts and components. In addition to this, there are various general tool room services on offer, including grinding, polishing, heat treatments, spot-welding and welding, soldering, drilling and reaming. All of which are part of the many manufacturing solutions and processes that we provide.

We utilize hand folding or dedicated hard tool forms to form components using the photo etching process. We also offer a service for component stamping. This is completed by using bespoke press tools or progression tooling, depending on the volume of components required.

We offer a wide variety of photo etching processes to suit your needs, and can easily produce components to your specifications, thanks to the flexibility of the processes we use. For more information on the rest of the services we offer

Trapped Molding

The trapped silicone method uses a specially blended silicone elastomer which at a select temperature expands to a known value. This process provides consolidation pressures in excess of what is achievable from an autoclave. The high internal molding pressures generated are sometimes combined with bladders which are inflated at different times during the cure cycle to specifically consolidate certain sections of the laminate. This process can be used in most structures and is uniquely suited to produce internal ribs and bulkheads.

Advance Processes

A significant section of todays truly complex composite structures relies on traditional composite geometry mated with high precision features which would commonly be more suited to plastic mold injection operations. We have developed techniques which specifically address theses challenges and are capable of generating high fidelity, void free, precision composite interfaces.

Our unique processing of UAV composite structures utilizes an out of autoclave technique which is capable of delivering selective pressures between 50 and 200 psi.

3D Printing

Additive manufacturing (AM), or 3D printing, is becoming more common in the aerospace tooling realm. Production tooling can be made quickly and on-demand, which helps the tooling industry keep pace with accelerating composite part design cycles and demand for faster overall part processing speeds.

Process DFM

Our organization is often initially selected as a second source on existing programs to offer an alternative approach which is nimble, cost effective and explicitly reliant on unconventional and unique manufacturing techniques to succeed where others have failed.   These programs often involve manufacturing advanced composite structures within programs which are currently operating outside the expected cost structure.  More often than not our role as second source is quickly transitioned to primary source vendor once the benefits of our manufacturing principals have been applied to the program.  We have successfully applied the Design to Unit Production Cost method to Naval Systems, Unmanned Aircraft and extremely complex composite laminates.

Plant and Machinery

joity cnc.jpg

CNC milling 4 Axis

  • High dynamics support rapid up to 30 m/min.

  • Optimum surface quality for Die-Mould application.

  • High precision 12000 rpm, BT 40 spindle.

  • Fast Auto tool changing, just 2.4 sec.

  • Wider high precisions liner motion guide ways.

VF2.webp

CNC Milling 3 Axis

SPINDLES

  • 12,000-rpm Spindle 

TOOL CHANGERS

  • High-Speed 30+1 Side-Mount 

CHIP & COOLANT MANAGEMENT

  • Window Air Blast 

  • 55-Gallon Coolant Tank 

  • Variable Flow Coolant 

THE HAAS CONTROL

  • Control Touch Screen 

  • Media Display M-Code; M130 

  • HaasConnect: Remote monitoring 

  • Early Power-Failure Detection Module 

  • Ethernet Interface 

  • WiFi Connection for the Haas Control 

  • Safe Run 

  • HaasDrop 

  • Rigid Tapping 

  • Standard Program Memory, 1 GB 

EDM-Die-Sinker-Machine.jpg

EDM Die sinking machine

50 AMPS bed size 500x300x300 

Die Sinking EDM also known as Electrical discharge machine (Electro Erosion), it is mainly used for processing molds and parts with complex shaped holes and cavities; processing various conductive materials, such as cemented carbide and hardened steel, etc.; processing deep and thin holes, special-shaped holes, deep grooves, narrow slits and Cutting thin slices, etc.; processing various forming tools, templates and thread ring gauges and other tools.

As the top machine manufacturers park, Our EDM machine can process the mirror effect. It is the best spark machine today. The processed molds can be directly used in production without saving molds, saving labor and improving efficiency. Moreover, the precision of the mirror sparking machine High, especially in the application of precision molds, the advantages are obvious.

wire edm.jpg

Wire EDM

Technical Specifications

Table Travel X,Y Axis (mm)

250 x 320

Work Table Size L x W (mm)

380 x 525

Maximum Work Piece Thickness (mm)

300

Maximum Taper / 100 mm Thickness

3° (Standard)

30° (Optional)

Maximum Work Piece Weight (kgs)

300

Machine Weight (kgs)

1600

Controller Specifications

Display

LCD Display

Control System

CNC

PC

Industrial PC #

Axis Control

4 - axes (X,Y,U,V)

X, Y Axis Guide Ways

Linear motion guide ways for X, Y axis

Resolution

0.001 mm

Wire Dia

0.18mm (Std.), 0.15mm, 0.12mm (Optional)

Interpolation

Linear and Circular

Programming

Incremental

Least Input Increment

0.001 mm

Least Command Input

0.001mm

Data Input / Output System

USB Port , Regular Keyboard and Mouse; Can read AutoCAD .dxf format

Input Power Supply

3 Phase, 415 Volts, 50 Hz with Neutral and Earth

Total Machine Load

1.5 KVA

Graphic Display

Graphic display of  part showing wire position

Processing and Data Entry

Dual Screen, New programs can be entered while cutting previous programme

Auto Stop

Auto Shut-off at the end of program

Dielectric Fluid

Soft water (D.M Water) + Gel

Dielectric Tank Capacity

55 Litres

Standard Features

  • Maximum Speed - 80mm2/Min.*

  • Machining accuracy - 0.01mm *

  • Best Surface Finish - Ra 1.25 to 1.75 *

  • A.C. - Not Required up to 40° C

  • BMXP pm-k system software controller works on Windows 10 operating platform

  • Inbuilt database for cutting different materials.

  • Coolant filtering system - Fine stainless steel wire mesh for coolant filter

  • No need to change wire guide for different diameters

  • Two axis DRO (Std.)

  • 4-Axes synthesizer to cut different profiles at top and bottom

  • Auto centre find, auto edge find, auto shut-off at wire breakage and auto stop at the end of the job

router.jpg

CNC 3 Axis Router

SPINDLES

  • 18000-rpm Spindle 

  • Window Air Blast 

  • Control Touch Screen 

  • Media Display M-Code; M130 

  • Early Power-Failure Detection Module 

  • Ethernet Interface 

  • WiFi Connection 

  • Safe Run 

  • HaasDrop 

  • Rigid Tapping 

  • Standard Program Memory, 1 GB 

jobber_lm (1).png

CNC Turning Center

Jobber series machines are a blend of cost-effectiveness & precision, ideal for most jobs.  Horizontal 2-axes turning center A2-6 spindle configurations with up to 320mm maximum turning diameter.  Linear Motion (LM) guideway  versatility for most turning applications