Why Use Composite Materials?

Why Use Composite Materials?

Composite materials offer many advantages in aircraft applications when compared to conventional materials such as metals. Increased strength, increased stiffness, reduced weight, reduced part count, and longer lifespan through greater fatigue limits and better corrosion resistance are benefits that can be achieved by replacing metals with composites.

Composite materials are quite versatile since their physical and mechanical properties can often be customized or “tuned” for an application by adjusting the composition of the specific material. For example, the mechanical properties in fiber reinforced composites are directional and aligned with the fiber orientation in the material, which allows more strength and stiffness to be selectively added to a structure by aligning the fiber orientation with the highest loads applied to the structure.


The use of composites also opens up more options for the design geometry of aircraft structures since they are particularly well suited for compound curves and organic shapes such as engine cowlings, wheel fairings, and wing tips. When properly applied, all of these advantages translate into higher performance for the application. Aircraft that can fly faster, higher, and farther while carrying greater payloads are made possible through the use of composite materials. 

Link to Course Terminology

Aerospace Composites Course

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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!5

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)