TECHNOLOGY STACK

At AFormX, we operate our own facilities that measure 950 square meters (10,200 square feet), designed to meet the rigorous demands of composite manufacturing. Located at the end of an industrial area, the building is secured by a chain-linked fence, ensuring a safe and controlled environment.

The production hall features wide entry doors, measuring 310 cm in width and 275 cm in height, enabling seamless handling of large composite parts and molds. To further streamline operations, the facility is equipped with two overhead cranes, each with a maximum load capacity of 1.5 tons, ensuring safe and efficient movement and handling of moulds and components throughout the workspace.

Additionally, the facility is equipped with central heating and air conditioning, to maintain temperature and humidity levels specified by each customers project. These conditions are meticulously monitored, with recorded data available for review on all projects. This transparency ensures that every project adheres to the highest quality standards and allows us to maintain full control over the production environment.

Our building is well-ventilated, brightly lit, and meticulously clean, creating a workplace that fosters precision and efficiency. These ideal working conditions enable the AFormX team to consistently deliver high-quality results in every project.

Cores
Our facility also features in-house CNC (1300mm x 1300mm x 300mm) foam cutting and milling capabilities, enabling us to produce custom core materials with high precision (0.1 mm). These cores, integral to the manufacturing of lightweight yet robust composite structures, are crafted to meet the strict standards required for high-quality aerospace components. With complete control over the cutting and milling process, we deliver tailored solutions that align with the unique specifications of each project. The CNC cutter is used also for cutting pieces from carbon or glass reinforces plates.

Cutting Fabric
All our cutting of fabric at AFormX is done by computer optimized tailoring plans. Traceability of materials is maintained throughout the cutting and sorting process.

At AFormX, we are in the process of acquiring a CNC fabric cutter, capable of handling dimensions of 1200 x 2000 mm and extending infinitely due to its roll-fed design. This advanced cutting technology ensures maximum material efficiency with minimal waste, a critical factor in maintaining cost optimization without compromising quality.

• Wet Lay-Up:
  We offer wet lay-up services for composite manufacturing, accommodating components of various sizes, ranging from small-scale lay-ups (10 mm x 10 mm x 10 mm) to large, complex structures (8000 mm x 5000 mm x 3000 mm). We are really good at producing consistent high quality results even with wet-lay-up technology.

• Wet Lay-Up with Vacuum Bagging:
  To achieve enhanced structural performance and resin uniformity, we use vacuum bagging techniques in conjunction with wet lay-ups. Our vacuum installation is such that we can regularly achieve absolute pressures in the milibar range. Apart from that our vacuum installation is protected against power-outages lasting for up to four hours.

• Resin vacuum Infusion:
  Our resin infusion process delivers lightweight yet high-strength components with superior mechanical properties and surface finishes. The method is suitable for small parts and large structures alike, providing precision and consistency for critical aerospace applications.

Each of these techniques is optimized to meet the specific requirements of the aerospace industry, ensuring precision, reliability, and unmatched performance in every project.

After the completion of the shells or skins we have a great facility for secondary bonding. Our workshop is equipped with a sandblasting system designed for the preparation of composite surfaces, ensuring optimal adhesion and readiness for further assembly or integration. We can use either structural glues or flox for secondary bonding.

We have vast experience with bonding large skins and closing of fuselages moulds. We diligently control the process of bonding and demoulding of larger parts to ensure the integrity and quality of both the skins and the moulds. If there are complications or challenges we have the risk management and experience to overcome it.

At AFormX, post-curing is a critical step in our composite manufacturing process, ensuring that all components achieve the desired mechanical, thermal, and dimensional properties required for high-performance aerospace applications. Our facility is equipped with 3 advanced in-house curing ovens, each meticulously designed for precision and consistency:

• Small Oven: Measuring 400 mm x 250 mm x 250 mm with a maximum temperature capacity of 200°C.
• Medium Oven: Measuring 3000 mm x 1000 mm x 1000 mm with a maximum temperature capacity of 120°C.
• Big Oven: Measuring 8000 mm x 3000 mm x 2700 mm with a maximum temperature capacity of 90°C.

Our medium and big ovens are fully programmable, allowing precise control of time and temperature profiles. For example, temperatures can be incrementally increased by 0.2°C per minute, ensuring controlled resin curing and optimal cross-linking. The ovens operate with an accuracy of ±2°C and feature automated temperature monitoring and adjustment systems. Temperature uniformity is ensured by means off 5 separate temperature sensors spaced out in key positions across the whole chamber of the oven.

Even in the largest oven the maximum difference between temperatures at different points is at most 2°C.

Safety is a priority; both ovens are equipped with fail-safe mechanisms that automatically shut down the system in case of temperature deviations. Additionally, the ovens maintain complete traceability and process records, providing a detailed history of curing cycles. This information is readily accessible to our customers, ensuring transparency and confidence in the quality of the final product.

These advanced post-curing capabilities enable AFormX to deliver reliable, high-performance composite components tailored to the exacting standards of the aerospace industry.

At AFormX, we specialize in the precise cutting and trimming of composite parts using advanced equipment and controlled environments to ensure the highest standards of quality.

In addition to CNC capabilities, our facility includes a dedicated sanding and trimming room measuring 7000 mm in length, 3800 mm in width, and 3300 mm in height. This room is equipped with advanced filtration systems, ventilation, and extraction units, ensuring a clean and safe workspace. Designed as an Ex zone (explosion-proof environment), it meets stringent safety regulations, allowing the use of compressed air and electric hand tools for trimming and finishing composite parts.

Our five axis CNC machine which we are in the process of acquiring will be capable of handling parts with dimensions up to 2000 x 3000 x 700 mm, enabling us to produce components with exceptional accuracy and repeatability for demanding aerospace applications.

This combination of precision machinery and a specialized workspace ensures that every component we produce meets the rigorous quality and safety standards required for aerospace applications.

At AFormX, we offer comprehensive painting and polishing services to ensure that every composite part meets the aesthetic and functional standards required by our customers.

The process begins with surface preparation, including sanding and filling, to create a flawless base for painting. Our wet spray painting technique is then applied to achieve an even, high-quality finish that meets industry-specific durability and appearance requirements.

After painting, we perform fine sanding and precision polishing to achieve a high-gloss finish. This final step not only enhances the visual appeal of the component but also ensures a smooth and durable surface, suitable for the most demanding applications in aviation.

With a commitment to quality and detail, our painting and polishing process delivers exceptional results, ensuring that every component not only performs flawlessly but also looks impeccable.

Our prototype composite workshop is fully equipped to support the development and manufacturing of high-performance composite components, leveraging advanced technologies and precision processes to meet the most demanding industry requirements.

We offer comprehensive mold-making services, including design, CNC milling, model creation, and final mold production. This end-to-end process ensures precision and quality at every stage, tailored to meet the unique requirements of your project.

For material validation, we provide destructive testing of composites, enabling thorough assessment of mechanical properties and structural integrity. Additionally, our workshop is equipped with a sandblasting system designed for the preparation of composite surfaces, ensuring optimal adhesion and readiness for further assembly or integration.

By combining these advanced capabilities with our expertise in composite manufacturing, we deliver innovative and high-quality solutions for prototype development, ensuring that each project exceeds expectations in performance and precision.

At AFormX, we prioritize the health and safety of our employees as a fundamental part of our operations. We are committed to providing a working environment that promotes well-being, prevents risks, and complies with the highest safety standards.

To achieve this, we implement the following measures:

• Regular health and safety training to ensure employees are equipped with the knowledge to maintain a safe workplace.
• State-of-the-art equipment and protective tools to minimize risks in all areas of work.
• Continuous monitoring and risk assessment to identify potential hazards and take proactive measures.
• Encouraging a culture of safety and open communication, where employees feel empowered to report concerns or suggest improvements.

By fostering a safe and supportive workplace, we ensure our team can thrive while maintaining the highest levels of productivity and innovation.