Technology

Why carbon?

* lighter than steel
* lighter than plastics
* lighter than aluminium
CO2 emission reduction in civil aircrafts

Product development

We engineer carbon-fibre components, taking into account most suitable materials and production technologies with the complete component simulation such as static, dynamic, crash and pedestrian impact analysis.

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Our customers provide us with the basic design of their components, typically in the form of the component A-surface in CAD, and product requirements such as mechanical, visual, safety, flammability. We engineer the components, taking into account the manufacturability during the DFM (Design for Manufacturing) study, working in close cooperation with the client for possible design changes which yield weight savings or cost reductions. We are able to pursue the complete component simulation such as static, dynamic, crash and pedestrian impact analysis. Moreover, we select the most suitable materials and production technologies given our wide experience, enabling us to design the components in the most effective way with primary focus on cost and performance. To validate the component design, all prototype components are tested.

Tooling design and manufacture

We design and manufacture, in-house, the tools and jigs needed for production, machining and assembly of our components. Our tool-shop is well equipped with numerous 3- and 5-axis CNC machines for epoxy patterns up to 6 x 3 m and aluminium tools up to 3 x 1.5 m.

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For large projects within a short time-frame, we outsource part of the tooling production to external tooling partners previously qualified by c2i. We pursue a 3D scan of every tool and jig to perform an accuracy check before they are used.

Composites production

We possess full capability for producing composites components in-house, from fabric cutting, lay-up, curing, machining to lacquering, painting, quality testing and assembly. We also machine foam cores and honeycombs in-house.

Quality Management System

c2i has an enhanced quality management system and its operations are certified by TUV Nord.

Composites production technologies

Autoclave / PREPREG: standard in civil aircraft, Formula 1 and best suited for carbon-look cosmetic parts, yielding the lightest possible components with best visual fibre alignment.

(HP)RTM: used for higher-volume automotive applications with cycle times far below one hour.

Prepreg press moulding: used for higher-volume automotive and aerospace applications and where a tooled surface finish is required from both component sides, with cycle times in minutes.

Bladder inflation moulding: for the production of hollow, monolithic structures, we lay-up prepreg in separate tool pieces, place a bladder inside, close the tool, then inflate the bladder during curing.

Equipment summary

Amount Equipment Description
7 5 axis milling machines

Up to 6 x 3 x 1,5 m for soft materials
Up to 3 x 1,5 x 0,8 m for aluminium tooling

2 3 axis milling machines
4 Autoclaves

Incl. 6 x 3m and 5 x 2.5m Boeing spec D6-49327 REV.E

3 Cutters

2 x Bullmer and 1 x Lectra, incl. bar code sticker application and automated nesting software

4 Presses

120T 2000 x 600 x 1200
200T 2000 x 1000 x 1500
315T 2000 x 1000 x 1300
800T 2500 x 1500 x 1800

1 RTM injection machine

Tartler 30 Bar

1 Painting line with 5 cabins

Carbon-look clear coating

1 Painting line with 4 cabins

Colour paint

1 3D measuring machine

Carl Zeiss: 3 x 2,5 x 1,6m

1 3D scanner

Steinbichler Comet

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