Welcome to the DarkAero Aerospace Composites Course!

1. Introduction to Aerospace Composites

• Welcome to the DarkAero Aerospace Composites Course!3

• What are Aerospace Composites?

• Why Use Composite Materials?

• Mechanics of Materials

• Composites vs Metals

• Defining Design Requirements - Wing Example1

2. Fiber Reinforcements

• Carbon Fiber2

• Glass Fiber

• Aramid Fiber

• Boron Fiber3

• Other Fiber Types2

• Tensile Strength - Fibers vs Metals

• Specific Strength - Fibers vs Metals

• Tensile Modulus - Fibers vs Metals

• Specific Modulus - Fibers vs Metals

• Elongation at Break - Fibers vs Metals

• Density - Fibers vs Metals

• Cloth Coordinate System Explained

• Unidirectional Weaves

• Plain Weaves

• Twill Weaves

• Multiaxial Non-Crimp Fabric

• Other Weave Types

• How Fiber Grades Vary by Manufacturer

• Understanding Cloth Nomenclature

• Key Points on Fiber Reinforcement4

3. Matrix Materials (Resin)

• Polymer Matrix Materials - Thermoset vs Thermoplastic

• Overview of Thermoset Matrix Materials

• Epoxy Resins

• Epoxy - Understanding the Technical Datasheet

• Vinyl Ester Resins

• Polyester Resins

• Phenolic Resins

• Key Points on Matrix Materials

4. Coupling Agents

• Coupling Agents

5. Core Materials

• Overview of Core Materials

• Foam Cores2

• Honeycomb Core Materials3

• Soric Infusible Core Material

• Other Core Materials2

• Key Points on Core Materials

6. Manufacturing Processes

• Wet Layup

• Wet Layup + Vacuum Bag2

• Infusion6

• Infusion Demonstration11

• Out-of-Autoclave Prepreg

• Autoclave Prepreg4

• Key Points on Manufacturing Processes

7. Curing

• Measuring Cure

• Mechanical Properties

• Thermal Properties

• Key Points on Curing

8. Post Processing

• Demolding

• Trimming

• Inspection and Quality Checks - Defects

• Quality Inspection Tools - Infrared Camera

• Quality Inspection Tools - Hardness and Thickness

• Quality Inspection Tools - Tap Testing Hammer

• Quality Inspection Tools - X-Ray

• Quality Inspection - Ultrasonic Testing

• Surface Finishing

9. Composite Assemblies

• Bonding

• Bonding Failures & Bonded Joint Geometry

• Adhesive Types

• Bonding Procedure4

• Fasteners2

• Hardpoints2

• Key Points on Composite Assemblies

10. Designing Composite Structures

• Establishing Requirements

• Composites vs Metals vs Plastics2

• Selection of Fiber, Matrix, Core, & Process

• Fiber Orientation and Layup Schedule Guidelines

• Composite Layup Guidelines - Rule 16

• Composite Layup Guidelines - Rule 2

• Composite Layup Guidelines - Rule 3

• Composite Layup Guidelines - Rule 42

• Composite Layup Guidelines - Carpet Plots

11. Testing

• Testing Structures - The Building Block Approach

• Standardized Tests

• Building Block Approach on the DarkAero 1 2

12. Composite Repair

• Damage Evaluation

• Repair Procedures

• Thank You for Taking the Course!9

Appendix

• Appendix A - Terminology

• Appendix B - Core Materials Comparison Table

• Appendix C - Weave Types Comparison Table

• Appendix D - Manufacturing Process Comparison Table

• Appendix E - Infusion Resin Material Properties

• Appendix F - Example Fiber to Resin Ratio Calculation4

• Appendix G - References

• Purchase Guide (Updated 09/04/2025)

• Infusion Process Guide (PDF)

• Composite Bonding Process Guide (PDF)

• DarkAero Aluminum Mold Support Structure Plans (Updated 06/30/2023)