Date: Apr 15, 2013 Source: MDA (
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A faster, greener process to replicate aircraft, rotorcraft, and automotive parts is taking root in northern Nevada, thanks to an enterprising company that has learned from lessons gleaned from MDA contract work.
Nevada Composites, Inc. (Dayton, NV), whose leaders emerged from MDA-funded 2Phase Technologies, developed a tooling system capable of producing ultra-lightweight ceramic replacement parts using environmentally friendly materials that leave minimal cleanup residue. In recent years, Nevada Composites has been advancing and successfully commercializing its tooling technology knowhow, which builds upon experience gleaned during MDA-funded SBIR projects.
The process, known as Green-Aero?, starts with Nevada Composites engineers taking a CAD model of the part to be replicated (or a model of the damaged part itself). From that design, the engineers produce a mold using a porous solution and an inorganic binder material—with final parts being cast from composite materials and thermally hardened. Green-Aero does not function as a reusable tool replication system, but as a tool to create one-off parts that are lightweight and inexpensive—and that clean up with little mess.
The company, founded in 2008, has landed several contracts with a government client and with a commercial aircraft manufacturer in need of replacement engine components. The company also is looking at the potential of replicating large parts for rotorcraft and has done some small-scale work fabricating replacement parts for motorcycles.
Nevada Composites is a family-owned, small business that develops ceramic and composite prototypes and replacement parts using innovative manufacturing processes that require less material, have stronger tolerances to heat, and are environmentally friendly.
