Product Design for Advanced Composites

Advanced composites are well known for their sophisticated strength and the ability to facilitate even the most complex engineering and design structures. Many disruptive technologies can be used to design products with composite materials in aerospace design.

Airbus used composite aerospace manufacturing in 1983 for its rudders. As manufacturing tools became more widespread, it resulted in industry-wide adoption because composite materials are 20% lighter than previous materials and offer lower production times.

With the development of advanced composites, it turned out that the material is also damage-resistant.


How Computer-Aided Composites Designs Are Made

Creating Advanced Composite Design Files

Composite manufacturing is dependent heavily on modeling the structure in a computer-aided design (CAD) program. The program helps engineers create specific dimensions and angles that would serve the product’s purpose best. Engineers can also use raw data to simulate how the material will act during the manufacturing process and create a buffer for error(s).

SolidWorks is one of the most common CAD programs in the industry. The program allows for three-dimensional representation and modeling.  It can be used in the building of mechanical, electrical, and software elements. considers material elasticity, plasticity, strength, conductivity, and other properties.


Structural Analysis of Designs

A finite element analysis (FEA) software is used to analyze and scrutinize the design to find any weaknesses or errors. The software identifies the design’s structural properties and the material used to predict the mechanical stress and strain it can bear.

These virtual objects need to be tested rigorously to identify any issues to be dealt with in the design phase, as CAD files.



A physical model is made after a viable design has been created; this is mainly the case with large orders working on composite material for aerospace design. An advanced composites engineer tests the composite material’s compression, reactivity, and more to ensure the prototype is up to client specifications.


If there are any issues, the composite prototype is broken down and analyzed. If not, mass production begins.


Advanced composite in aerospace manufacturing needs to be precise. Even a centimeter above or below can mean disaster in the air, resulting in loss of life and millions of dollars worth of investment.

Hence, during production runs, a quality assurance employee is stationed to inspect every piece created. This employee may also have flight safety training, which further helps them understand what they must do and the potential ramifications of mistakes.


To make sure you only work with the best product designs for advanced composites, make sure you work with engineers with extensive industry experience and reduce costs for your large orders.


Pacific Aerospace Corp (PAC) has a wide range of industry experts and mass advanced composite aerospace manufacturing capacities to help you make short work of even the most extensive requirements. Give us a call today!