Composite materials have revolutionised the aerospace industry, providing a blend of strength and lightness that is critical for modern aircraft performance. However, bonding these materials, especially when combined with light metals, presents unique challenges. Traditional heating methods often fall short in terms of uniformity of application, leaving room for innovation. One notable case of overcoming these challenges is Boeing Aerostructures’ transition from conventional heat lamps to a custom-designed composite heating jacket solution developed in collaboration with SBH Solutions and LMK Thermosafe. 

Boeing’s challenge: Uniformity of composite curing using conventional methods not optimum

In the manufacturing of Boeing Aerostructures’ composite and aluminium wing parts, the bonding process relied on a “forest of heat lamps” to cure the sealant bonding composite parts. While this method was widely used, it came with significant drawbacks. The process was cumbersome, required meticulous positioning of each heat source, and consumed large amounts of energy. Most critically, the uneven distribution of heat often led to inconsistent curing results, which could impact the integrity of the wing part’s structure. 

Engineers at Boeing recognised the need for a more efficient and reliable composite heating solution that could ensure uniform heat application across complex surfaces, reduce energy consumption, and streamline the process. 

Solutions: Custom Composite Heating Jackets 

An engineer at Boeing decided it was time to rethink the entire composite curing process. Instead of relying on outdated heat lamps, he turned to SBH Solutions in search of a smarter, more efficient alternative. 

SBH Solutions offers a broad range of LMK Thermosafe flexible heating jackets for various industrial heating applications. One product, the HHD insulated heating jacket—originally designed for heating industrial drums—seemed like the perfect fit for Boeing’s needs. These flexible heating blankets are portable, effective, and energy-efficient, making them an ideal solution for composite curing. The teams from Boeing, SBH Solutions and LMK Thermosafe put the idea to the test to see how to heat composite material better. The first trials involved using one of SBH’s standard heating jackets, laid flat over the composite parts of the wing part to see if it could cure the bonding material evenly. 

The results were very promising when used with separate more accurate thermostat controls than the capillary thermostat so effective for drum heating. The heating jacket delivered steady, uniform heat, curing materials more uniformly than the heat lamps. Encouraged by these early results, both teams got to work refining the design. Within a short time frame, a custom composite heat blanket tailored to the specific needs of Boeing’s 777 composite wing part bonding process was delivered to the dimensions required and with more precise thermostatic control. It was designed to lay flat over large surface areas, providing consistent heat across the entire piece. 

Results

After the heat blankets for composites were in use, the benefits of custom composite heating jackets became immediately clear: 

• Even heating: Unlike the old heat lamps, the blankets provided uniform heat across the entire wing, ensuring the sealant was cured perfectly every time. 
• Energy efficiency: The new heating method used far less energy, reducing costs and the factory’s environmental footprint. 
• Simplified process: No more fiddling with multiple heat lamps. The blankets were easy to set up and monitor, making the process smoother and less prone to human error. 
• Scalability: Boeing didn’t stop with just the wing parts. The success of the heating blankets led to their use in other areas, like the bonding process for the 787 rudder. It was a scalable solution that worked across different components with heater jackets sized to specific requirements. 

Conclusion 

The collaboration between Boeing Aerostructures, SBH Solutions and LMK Thermosafe showcases how a custom composite heating blanket solution can improve the entire process of curing composite materials. The success of this solution extends beyond aerospace.

As industries like automotive, wind energy, and marine engineering increasingly turn to composite materials, the demand for efficient and reliable curing solutions has grown and continues to find new applications. Our composite curing heating solutions have the potential to enhance efficiency across a wide range of production processes, driving improvements in both performance and cost-effectiveness. 

Want to customise a heating solution for your project?

Get in touch with us via email at [email protected] or call (08) 7122 1114, and our team will help you to find the best solution.