Aerospace Composites Course
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1. Introduction to Aerospace Composites

Welcome to the DarkAero Aerospace Composites Course!
What are Aerospace Composites?
Why Use Composite Materials?
Mechanics of Materials
Composites vs Metals
Defining Design Requirements - Wing Example
2. Fiber Reinforcements

Carbon Fiber
Glass Fiber
Aramid Fiber
Boron Fiber
Other Fiber Types
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
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
Honeycomb Core Materials
Soric Infusible Core Material
Other Core Materials
Key Points on Core Materials
6. Manufacturing Processes

Wet Layup
Wet Layup + Vacuum Bag
Infusion
Infusion Demonstration
Out-of-Autoclave Prepreg
Autoclave Prepreg
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
Finishing
9. Composite Assemblies

Bonding
Bonding Failures & Bonded Joint Geometry
Adhesive Types
Bonding Procedure
Fasteners
Hardpoints
Key Points on Composite Assemblies
10. Designing Composite Structures

Establishing Requirements
Composites vs Metals vs Plastics
Selection of Fiber, Matrix, Core, & Process
Fiber Orientation and Layup Schedule Guidelines
Composite Layup Guidelines - Rule 1
Composite Layup Guidelines - Rule 2
Composite Layup Guidelines - Rule 3
Composite Layup Guidelines - Rule 4
Composite Layup Guidelines - Carpet Plots
11. Testing

Testing Structures - The Building Block Approach
Standardized Tests
Building Block Approach on the DarkAero 1
12. Composite Repair

Damage Evaluation
Repair Procedures
Thank You for Taking the Course!
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
Appendix G - References
Purchase Guide (Updated 05/14/2024)
Infusion Process Guide (PDF)
Composite Bonding Process Guide (PDF)
DarkAero Aluminum Mold Support Structure Plans (Updated 06/30/2023)

8. Post Processing

9 Lessons