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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 Example
1
2. Fiber Reinforcements
Carbon Fiber
2
Glass Fiber
Aramid Fiber
Boron Fiber
3
Other Fiber Types
2
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 Reinforcement
4
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 Cores
2
Honeycomb Core Materials
3
Soric Infusible Core Material
Other Core Materials
2
Key Points on Core Materials
6. Manufacturing Processes
Wet Layup
Wet Layup + Vacuum Bag
2
Infusion
6
Infusion Demonstration
11
Out-of-Autoclave Prepreg
Autoclave Prepreg
4
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 Procedure
4
Fasteners
2
Hardpoints
2
Key Points on Composite Assemblies
10. Designing Composite Structures
Establishing Requirements
Composites vs Metals vs Plastics
2
Selection of Fiber, Matrix, Core, & Process
Fiber Orientation and Layup Schedule Guidelines
Composite Layup Guidelines - Rule 1
6
Composite Layup Guidelines - Rule 2
Composite Layup Guidelines - Rule 3
Composite Layup Guidelines - Rule 4
2
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 Calculation
4
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)
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Aerospace Composites Course
Buy now
Learn more
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 Example
1
2. Fiber Reinforcements
Carbon Fiber
2
Glass Fiber
Aramid Fiber
Boron Fiber
3
Other Fiber Types
2
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 Reinforcement
4
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 Cores
2
Honeycomb Core Materials
3
Soric Infusible Core Material
Other Core Materials
2
Key Points on Core Materials
6. Manufacturing Processes
Wet Layup
Wet Layup + Vacuum Bag
2
Infusion
6
Infusion Demonstration
11
Out-of-Autoclave Prepreg
Autoclave Prepreg
4
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 Procedure
4
Fasteners
2
Hardpoints
2
Key Points on Composite Assemblies
10. Designing Composite Structures
Establishing Requirements
Composites vs Metals vs Plastics
2
Selection of Fiber, Matrix, Core, & Process
Fiber Orientation and Layup Schedule Guidelines
Composite Layup Guidelines - Rule 1
6
Composite Layup Guidelines - Rule 2
Composite Layup Guidelines - Rule 3
Composite Layup Guidelines - Rule 4
2
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 Calculation
4
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)