Category: Aerospace
BREAKING THE MOULD – Why Liquid Resin is the Future of Aerospace Structures
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For decades, autoclaved prepreg has been the undisputed benchmark in aerospace composites. But as the industry faces mounting pressure to scale production, reduce emissions and control costs, all while maintaining uncompromising quality — there is a new contender rising to meet the challenge: liquid resin.
In a pivotal whitepaper titled Liquid Resin: The Journey Towards Future Aircraft Structures, Composite Integration presents a compelling argument for liquid composite moulding as a viable and, in many respects, superior alternative to traditional methods. From propellers to thrust reversers, nacelles to demonstrator wings, the evidence is increasingly clear. Resin Transfer Moulding (RTM) and Resin Infusion (RI) are not only capable of meeting aerospace-grade requirements, they are ready to reshape the industry’s manufacturing playbook.
So what’s driving this change?
A Sector Under Pressure
The aviation world stands at a critical turning point. Demand for commercial aircraft continues to soar, with Airbus alone holding a backlog of nearly 9,000 aircraft. Simultaneously, emerging electric vertical take-off and landing (eVTOL) companies like Vertical Aerospace are forecasting even higher production volumes — up to 300 aircraft per month. That scale demands a shift in how we build composite structures.
Traditional prepreg and autoclave methods, while proven in quality, are slow, expensive and highly energy-intensive. They simply
do not scale to the volumes or meet the sustainability targets modern aerospace manufacturing now demands. Composite Integration argues that liquid resin processes, with faster cycle times, lower energy footprints, and proven quality metrics, are the answer.
Quality Without Compromise
The standout message from Composite Integration’s research is that liquid resin processes can now deliver the same exceptional laminate quality as prepreg methods, while offering significant reductions in cost, weight and energy usage.
Through years of internal development and collaborative industry programmes, including projects with Safran Nacelles,
GKN Aerospace and Dowty Propellers, the company has refined a rigorous, data-led methodology for RTM and Resin Infusion. The result? Laminates with fibre volume fractions close to 60% and virtually zero void content, consistently produced at scale.
In real terms, this translates to demonstrator components like business jet thrust reversers and nacelle skins that not only meet stringent aerospace standards but also outperform traditional parts in terms of environmental impact. One prototype even showed a 60% reduction in carbon footprint over its prepreg counterpart.
Process Science Meets Practical Automation
While much of the industry still debates the finer points of resin pressure regimes and membrane strategies, Composite Integration has developed the tools to take the guesswork out of liquid resin moulding.
Their CIJECT range of machines is the beating heart of this transformation. Designed with precision process control in mind, CIJECT systems manage every aspect of the moulding cycle, from resin degassing and temperature control to real- time pressure regulation and digital logging. Crucially, they do so with software-driven automation that makes complex processes accessible to operators, reducing the chance of error and ensuring consistency from part to part.
Pressure accuracy within a few millibars. Resin flow monitored and adjusted in real- time. Automated process steps that can be programmed and repeated at scale. These are not theoretical capabilities; they are features already embedded into machines supporting major aerospace production lines today.
And the infrastructure around these machines is just as important. Composite Integration has invested heavily in tools for fabric permeability measurement, ply compression analysis and bubble quantification, giving engineers real-world data to guide design and process choices.
‘One prototype even showed a 60% reduction in carbon footprint over its prepreg counterpart.’
The RTM Renaissance
Resin Transfer Moulding is not new, but its industrialisation for aerospace at scale is
a frontier few have conquered. Composite Integration’s work with RTM presses and closed-mould automation has yielded impressive results, particularly in the production of propeller blades and structural wing components.
Consider the Dowty Propellers programme, where high-performance components
are manufactured using over-braided dry preforms, injected over foam cores. With hundreds of thousands of flying hours,
these parts are proven in the sky. Now, the challenge is scaling that reliability to match the production demands of next-gen eVTOLs and regional aircraft.
Composite Integration’s response? Fully integrated RTM cells capable of producing multiple sophisticated mouldings every hour. These systems manage temperature, flow, injection ratios and even resin ageing, logging every variable in real-time. They also feature advanced resin management strategies, including non-vented injection and tight tolerance process envelopes.
Rethinking Resin Infusion
While RTM handles closed-mould precision, Resin Infusion offers flexibility and scalability. And contrary to outdated perceptions, it
can now achieve the fibre fractions, weight savings and quality metrics required for high- performance flight parts.
During the ProPound project with Safran Nacelles, Composite Integration helped define critical Resin Infusion parameters for aerospace-grade laminates. The outcome was a tightly controlled process that eliminated the need for double-bagging or semi-permeable membranes. Instead, clear infusion strategies and custom consumables, combined with precise control over resin pressure and degassing, led to robust, repeatable results.
One standout example was the business jet thrust reverser skin, infused using Hexcel RTM6 resin, multi-axial carbon and lightning strike materials. It was not only lighter and greener than its prepreg counterpart, but also faster and more cost-effective to produce.
From TRL to Production
Perhaps most impressively, Composite Integration does not just build machines, they support an entire ecosystem of composite development. From early-stage R&D and demonstrator part production to full-scale manufacturing cells, the company’s team works closely with customers across all technology readiness levels.
A typical large-scale liquid resin infusion machine for aerospace applications capable of either Resin Infusion or Resin Transfer Moulding.
It is this integrated approach, combining material science, process engineering and turnkey automation, that enables successful transitions from concept to production. With partners spanning aerospace, wind energy and marine sectors, Composite Integration brings a uniquely cross-sector perspective to problem-solving. And crucially, we are not standing still.
Ongoing developments include enhanced degassing technologies, in-house permeability characterisation tools and support for 2K resin systems with advanced ratio verification. These are the kinds of innovations that will power the next generation of lightweight, high-performance and environmentally responsible aircraft.
The Future is Liquid
As demand grows and sustainability becomes non-negotiable, aerospace manufacturing must evolve. Composite Integration has shown that liquid resin is not just a viable alternative, it is a proven, scalable and future-ready solution.
Whether you are developing eVTOL propellers, commercial wing structures or high-rate nacelle components, now is the time to explore what liquid resin moulding can do for your operations.
Liquid Resin | The Journey Towards Future Aircraft Structures
We are pleased to share a new technical whitepaper, “Liquid Resin – The Journey Towards Future Aircraft Structures,” exploring how Resin Infusion (RI) and Resin Transfer Moulding (RTM) are redefining aerospace composite manufacturing.
This is How You Achieve Quality at Rate
FOR THOSE WHO THINK IT CAN’T BE DONE.
This is How You Achieve Quality at Rate
In the race to fulfil demand and reduce backlogs, aerospace manufacturers are turning away from slow, wasteful and capital intensive pre-preg processes. The more nimble and efficient RTM (Resin Transfer Moulding) & Direct Infusion techniques are now at the forefront. Here’s why…
In the fast-paced and rigorously demanding realm of aerospace manufacturing, the industry is faced with significant challenges as it strides into the future. The primary hurdle is the production of high-quality aerospace components that not only meet but surpass the increasingly stringent standards of performance, durability, and safety. This challenge is magnified by the accelerating pace of demand from both commercial airlines and defence sectors, each pushing for more sophisticated and reliable components with quicker turnaround times.
Adding to the complexity is the environmental impact of manufacturing processes. As global attention shifts towards sustainability, aerospace manufacturers are under significant pressure to reduce their carbon footprints, manage waste more effectively, and optimise energy consumption—all without compromising the high quality and precision that aerospace parts require.
Economic pressures further complicate the landscape. The high cost of raw materials, the need for specialised labour, and the significant capital investment in manufacturing infrastructure pose substantial barriers to scalability and efficiency. These economic factors are coupled with the technological challenges of integrating the latest advancements in materials science and engineering, ensuring that every component can withstand extreme conditions and rigorous use.
Why Infusion Over Pre-Preg?
Traditionally, the aerospace industry has favoured pre-preg materials for their quality. However, these materials come with inherent limitations such as high costs, extensive storage requirements, and labour-intensive processes that escalate operational expenses and restrict scalability.
Challenges with Pre-Preg:
Pre-preg materials are expensive. Add into the mix specialised storage and often the need for autoclave curing, the costs quickly mount up.
Equipment Requirements:
The use of pre-preg materials often necessitates autoclave curing, requiring substantial investment in specialised equipment.
Limited Scalability
: The intricate handling and laying up processes restrict the scalability of pre-preg, making it less adaptable for meeting increased demands.
Extended Curing Times:
Pre-preg materials typically require prolonged curing times in autoclaves, leading to bottlenecks in production cycles and reduced manufacturing throughput.
Labour Intensity:
The process of laying up pre-preg materials is labour-intensive and requires a high level of skill from workers, limiting production speed and increasing costs due to the need for skilled labour.
Storage Limitations:
Pre-preg materials must be stored in refrigerated conditions to prevent premature curing, which imposes additional logistics and storage costs.
Limited Shelf Life:
Pre-preg material chemicals have a fixed shelf life, beyond which
their performance characteristics may degrade, leading to potential waste and increased operational costs if the materials are not utilised promptly.
Inflexibility in Design Changes:
Pre-preg layup schedules and mould designs are difficult
and costly to alter, inhibiting responsiveness to new design requirements or improvements.
Why Choose RTM & Direct Infusion?
Dedicated to our mantra ‘there’s always a better way,’ we have invested over 2 decades developing Resin Transfer Moulding (RTM) and Direct Infusion. These technologies exemplify innovation in manufacturing, where precision engineering ensures uniform resin distribution—critical for achieving the highest structural integrity with minimal voids.
Our processes ensure components consistently meet rigorous aerospace standards, thereby maintaining quality at an increased production rate. CIJECT further accelerates the production process without compromising on quality, optimising infusion for faster cycle times and higher throughput.
“CIJECT equipment plays a pivotal role in aerospace manufacture, giving you complete control and verification over the entire manufacturing process.” Tim Searle, R&D Director
Key Benefits of RTM & Direct Infusion with CIJECT
Consistent High Quality
CIJECT ensures each component consistently meets or exceeds stringent aerospace standards, thanks to its precise control over resin preparation, mixing, injection, distribution and curing processes. This level of control ensures every part follows the same repeatable process, maintaining uniformity in quality and performance.
Cost Efficiency
One of the standout benefits of using CIJECT equipment is its ability to reduce material waste. The system’s precise infusion techniques ensure that only the necessary amount of resin
is used, minimising excess. This not only reduces the cost of materials but also lessens the environmental impact associated with waste disposal. Additionally, the reduced need for rework and lower scrap rates contribute to overall cost savings, making the manufacturing process more economical and sustainable.
Quality at Rate
CIJECT allows for acceleration of production timelines without sacrificing quality output. By integrating advanced automation and control systems, the equipment maintains a rapid production pace, enabling manufacturers to meet high demand without delays. Efficiency is achieved through streamlined processes, with each step from resin preparation to component curing optimised for speed and precision.
Scalability & Flexibility
CIJECT equipment is highly adaptable and customisable, capable of handling a wide range of component sizes and complexities. This adaptability allows for manufacture of small intricate parts to large structural components, be it RTM or Infusion. Easily scale your production up or down, based on demand, without the need for significant adjustments in the production setup. New product designs can be accommodated quickly and efficiently.
Pushing Boundaries
Composite Integration is enabling leading aerospace manufacturers to pioneer advancements in the industry, continuously driving innovation and efficiency.
Our partnership with Safran has been crucial in optimising low-cost infusion technologies, establishing key process parameters that now guide our high- performance infusion methods.
Additionally, as associate members of the National Composites Centre, we are actively involved in the Airbus ‘Wing of Tomorrow’ programme, contributing to the development of innovative wing designs for the next generation of fuel-efficient and electric aircraft.
Understanding Your Challenges: How we can help
Improved Processes: Leverage our deep industry knowledge and technical expertise through our process consultancy services. We help clients optimise their manufacturing processes from initial design to final production.
Optimised Quality & Efficiency: Our dedicated R&D team continuously refine and enhance the capabilities of our Direct Infusion technology, to stay at the forefront of composite manufacturing.
Rapid Prototyping Services: We offer prototyping services that enable quick turnaround times for test components, crucial for iterative design processes, allowing for fast-paced developments and improvements.
Reduced CAPEX & OPEX: Benefit from cutting-edge equipment that decreases both.
Significant Weight Savings: Achieve designs that enhance fuel efficiency and performance.
Increased Component Durability: Extend the lifespan of components and reduce ongoing maintenance needs.
On-Site Customisation & Expert Setup: Ensure seamless integration of our machinery into your production lines.
Comprehensive Training and Ongoing Assistance: Equip your team with the skills
to maximise the benefits of RTM & Direct Infusion technology, supported by continuous expert guidance.
“Others may provide the equipment; we go even further. From guidance throughout your project, to onsite installation, we help you develop quality processes and parts at scale” David Raynor, Sales Director