Composite & Metal Bonding

In our modern Composite and Metal Bonging Facilities awarded with NADCAP, ISO 9001 and AS9100 certificates, production of all kinds of superior quality and precise composite tools and parts, needed for the aerospace and satellite industry, is accomplished. Carbon fiber, kevlar and glass fiber based prepreg materials or dry fabrics are laid up buy means of CNC controlled automated machines or by hand and cured in autoclaves. Mainly the national projects such as ANKA, T129 ATAK, HÜRKUŞ and the leader Aerospace companies Boeing, Airbus, Lockheed Martin, Northrop Grumman, Bombardier and Leonardo are supplied with these highest quality Composite details or subassemblies, with maximum delivery performance.


Hand lay-up is the most common composite part production method in the aerospace industry. Pre-cut layers are laid on the lay-up moulds by experienced operators, according to the directional and positional data given by design. The lay up operations are performed in the 100.000 class clean rooms, where the temperature, pressure, humidity and dust are controlled.

During composite part hand lay up operations, the advanced technology precise laser projection systems are utilized. The laser projection systems which are located over the lay up area, reflects the positional and directional data of the fabric layers, on the lay-up moulds, thus leading the operators to place the layers with an accuracy of +/- 0,38 mm.


The manufacturing process of a blade, which is the most critical part of an helicopter, is a combination of  various complex processes,  carried by laying down the spar by means of an Automatic Lay-up Machine, proceeding by a compaction and hot forming press cure cycle, assembling all the parts on special tools and fixtures, and finally completed by painting and static balancing operations.

Performs the lay-up and linear cut of  fabric material layers on the tool,automatically.

Performs the compaction process (vacuuming and shaping) of the fabric material, which is laid down by ATL, on the forming tools.

is a hydraulic press, used in aerospace industry, for thermal forming operations. Heat is transferred to the moulds through lower platen of this press.

Sprays the pressurized dry blasting media via programmable nozzles,on the part which is moved at a certain speed. This process is used to prepare suitable surfaces prior to painting or bonding.


RTM (Resin Transfer Moulding) is a process in which preformed dry fabric material is located between upper and lower moulds, followed by resin injection, afterwards, curing operation is performed under controlled temperature, time and pressure. By RTM process, smooth and shiny surfaces are obtained at all sides of the part. TAI uses her own designed and manufactured preforming and injection equipment in aircraft part manufacturing.


Fiber placement process is being popular within the Aerospace Industry, especially used in the manufacturing of complex contoured aircraft parts. Thermoplastic or thermoset resin impregnated strip materials, with different thicknesses, are placed on the complex tools with the help of five or more axis head system, to support high production rates.


Autoclaves are industrial ovens that are used to cure composite aerospace parts under high temperature and pressure. Curing process includes the heat up, dwell and cool down process of the parts under a certain temperature rate, vacuum and pressure condition. During this cure period, the whole process is recorded and reported by means of automation systems.


Unlike from the ordinary milling machines, the precision milling machines used in the aerospace industry have a volumetric compensation ability and built to climatize the axis and machine environment. Thus, they are able to machine the composite skin panels and air inlet ducts having very low tolerances, within 0,1 mm accuracy. In TAI, the satellite and F35 parts are machined in these machines.


The precise drilling and routing operations of the composite aircraft parts are done by the help of high pressure water jet mixed with abrasive media. All kinds of parts up to 200 mm thickness, made of steel, titanium, aluminum or composite, can be machined by these 6 axes, using a mixture of high pressure (4400-6205 bar) water and abrasive material.


TAI has the ability of machining of different honeycomb materials, excessively used in aerospace industry, with 5 axis milling machines or robotic routing centers, using classical cutting tools or ultrasonic knife systems.

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