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	Brookhouse Composite Ltd – Plant List & Manufacturing Capabilities Manufacturing Facilities Freezer Material Storage Facilities Freezer No 1 5.48m x 5.48m x 2.74m high Freezer No 2 1.74m x 2.24m x 2.00m high Freezer No 3 7.50m x 3.30m x 2.40m high Freezer No 4 3.00m x 2.00m x 2.30m high All freezers incorporate:- Continuous temperature recording systems including audible alarms Shelf life monitoring systems Documented evidence of freezer efficiency Clean Room Environment There are three separate clean rooms totalling 14,000 sq ft. of environmentally controlled manufacturing floor space which are qualified up to Class 100,000 (US FED STD 209) / Class 8 (ISO 14644). Specializing in the manufacture of aircraft structural products utilizing pre– impregnated materials such as CFRP, GFRP and AFRP, film adhesives and bonded honeycomb cell structures, the manufactured items being cured at temperature and pressure using any of the five operational autoclaves. The clean rooms incorporate :- Continuous temperature and humidity monitoring including audible alarms Positive pressure rooms for prevention of particle ingress Weekly dust / particle count monitoring Three automated CNC ply profile cutting machines with off line programming Autoclave Facilities Autoclave 1 2m dia x 2.8m deep controlled by FGH P460 Autoclave Manager Range 0–200C / 0–100psi Autoclave 2 1.83m dia x 2.44m deep controlled by FGH P450 Autoclave Manager Range 0–200C / 0–100psi Autoclave 3 3.35m dia x 6.71m deep controlled by FGH P460 Autoclave Manager Range 0–200C / 0–90psi Autoclave 4 2.80m dia x 4.20m deep controlled by FGH P460 Autoclave Manager Range 0–200C / 0–100psi Autoclave 5 3.25m dia x 13.00m deep controlled by LBBC Autoclave Manager Range 0–200C / 0–100psi Autoclave 6 3.0m dia x 10m deep controlled by FGH P460 Autoclave Manager Range 0–200C / 0–100psi Resin Infusion Unroll Cutting M/C L to 4000 variable x W1600 mm Variable ply cut length machine Floor to machine cloth hoist max weight 190KG x 500mm dia Roll Reusable Vacuum Table 3.98 Mtr x 1.6 Mtr Auto Infusion Equipment, - 4 Off each comprising: 1 Off Control panel for fully automated or manual control Platten Press 300 Tonne heated Platten Press with 2.23 sq m bed. Ovens There are a range of ovens that are used for curing, forming and drying of components ranging in size from .25m x .25m x .25m up to 3.0m x 4.00m x 2.00m. All ovens can provide calibrated charting facilities where necessary. Temperature ranges from 0 –200°C. Ovens for resin infusion capability are identified below: Oven St - 1 Off FGH system P3022 Monitor, Control & Data log L4050 x W2250 x H2050mm Max Temp 180 +/-3oc Oven PR - 2 Off FGH system P3022 control & Data log L2550 x W2050 x H2050mm Max Temp 200 +/-3oc Oven RI - 4 Off FGH system P3022 control & Data log L3050 x W2050 x H2050mm Max Temp 200 +/-3oc Oven PA 1 Off FGH system P3022 control & Data log L1550 x W1520 x H2171mm Max Temp 180 +/-3oc   Non Destructive Testing (NDT) Facilities NDT inspection can be undertaken using a range of ultrasonic inspection devices. ‘C ‘ Scan Through Transmission Water Jet Inspection (6.00m x 2.00m x 0.70m) ‘C ‘ Scan Immersion Tank Inspection (2.00m x 1.00m x 0.50m) ‘A ‘ Scan Water Bubbler Inspection (1.00m x 0.50m) ‘A ‘ Scan Hand Held Rig Inspection NDT C-scan Ultrasonic Inspection system ‘C’ Scan Through Transmission Water Jet Inspection L4.50m x W1.00m NDT A-scan Ultrasonic Inspection system Omniscan Phased Array 16:128 & 1 UT Channel product 16 elements x L2.5 M with YY Connector Angled Beam, 5 MHZ Thermal Forming Machines Dedicated Facility Source Laminating (Glass Reinforced Polymers) Specializing in a variety of products including:- Wet lay up covers, furnishings, di–electric panel assemblies, radomes and radome panels using glass fibre/polyurethane foam core techniques, air conditioning ducting, aramid blast tubes and heat transferable insulation covers. Oven Forming Plastic forming Polyurethane and rohacell foam products Acrylic windows Machining A full range of composite machined details routed and finished to drawing specification. 5 Axis Composites CNC Routing Machine OSAI CNC controlled with advance ‘TEACH-IN’ system X3.6m, Y2.6m, Z1.2m. Max rpm, 24,000 (80m per minute) Twin bed Sealed enclosure Liquid cooling 5 Axis CNC Machine DMU50eVo linear 5 sided up to 5 axis simultaneous machining X500 x Y450 x Z400mm Range 20 - 24000rpm, 130 NM, 35KW, trav 80m/min 30 tool change positions Dust extraction system to remove carbon dust include air purge on measuring system CMM Machine W2000 x L3000 x H500 Poli Oxalis Machine with PC-DMIS CAD TM Software On-Off line programming Renishaw PH6 Probe Head Thermoforming Vacuum formed interior mouldings made from a variety of materials including polycarbonate, acrylic , ABS Royalite , Makrolon , Fromoplas , Schneller Aeroform etc . Acoustic Lagging Thermal lagging of pipes and ducting using materials such as Orcon foil, Microlite AD, Bestobell Viton Fabric with felt insulation, polyurethane foams and relevant adhesives. Detail Fitting Composite detail fabrication Metal details Sub – assemblies Door assemblies, floors, galleys etc. Acrylic Forming Acrylic forming of covers Acrylic window manufacture / repair Forming , Assembly , Bonding and Polishing One Stop Repair Shop Strip and survey Full composite / metal repair centre Paint finishing Paint Finishing There are Five spray booth/curing ovens for paint finishing processes. Paint Booth One Eurotecno 7.00m x 3.92m x 2.66m Range 0 – 80°C Paint Booth Two Eurotecno 7.00m x 3.92m x 2.66m Range 0 – 80°C Paint Booth Three Dalby 7.00m x 4.00m x 2.5m Range 0 – 90°C Paint Booth Four Dalby 7.00m x 4.00m x 2.50m Range 0 – 90°C Paint Booth Five Dalby 6.00m x 4.00m x 2.50m Range 0 – 90°C   Laboratory Brookhouse Composites Laboratory: Capability The Brookhouse Composites Laboratory is a 250 m² facility responsible for many aspects of process control and process assurance within the Brookhouse Composites manufacturing facility. Its primary capabilities are based around the following equipment:- Mechanical Testing Lloyd MX100 100kN Uniaxial Tension and Compression Mechanical Test Rig Is PC driven using Dapmat v3.3 Software includes fixtures and jigs for the performing of tests such as tensile strength, compressive strength, flexural strength, interlaminar shear strength, flat wise tensile strength and beam loading. Instron 3369 50 kN Uniaxial Tension and Compression Mechanical Test Rig Is PC driven using Bluehill v1.4 Software includes fixtures and jigs for the performing of tests such as tensile strength, compressive strength, flexural strength, interlaminar shear strength, flat wise tensile strength proof loading of small assemblies and beam loading. Also features extensometry for determining strain and modulus characteristics and an environmental chamber for performing test at elevated temperatures (up to 300 ° C) Instron 3367 30 KN Uniaxial Tension and Compression Mechanical Test Rig Is PC driven using Bluehill v1.4 Software includes fixtures and jigs for the performing of tests such as tensile strength, compressive strength, flexural strength, interlaminar shear strength, flat wise tensile strength proof loading of small assemblies and beam loading. Also features extensometry for determining strain and modulus characteristics. Instron 3382 100 kN Uniaxial Tension and Compression Mechanical Test Rig Is PC driven using Bluehill v2.3 Software includes fixtures and jigs for the performing of tests such as tensile strength, compressive strength, flexural strength, interlaminar shear strength, flat wise tensile strength proof loading of small assemblies and beam loading. Also features extensometry for determining strain and modulus characteristics. Strain Gauging 2 x Hottinger Baldwin Messtechnik Spider 8 Strain Gauge Data Logger 8 channel 4.8 kHz strain gauge data loggers to facilitate strain measurements through the mechanical testing of specimens. Fully recordable. Specialist Machining Benetec 500 Platesaw Test Piece Machining Facility Tight tolerance , high precision , water cooled , diamond bladed composites test piece machining facility assuring squareness and parallelism of test specimens for improved mechanical test accuracy. Thermal Analysis Testing 2 x Perkin Elmer Pyris Diamond Dynamic Mechanical Analyser ( DMA ) - Determines the glass transition temperature ( Tg ) of cured / uncured composite materials . Used as a proof of cure check for autoclave / oven curing Includes; tensile, single cantilever and dual cantilever loading modes. Capabilities include facility to purge under Nitrogen. Perkin Elmer Pyris Diamond Differential Scanning Calorimeter ( DSC ) featuring High Speed Scanning Capabilities ( H – DSC ) - Determines reaction kinetics of uncured resin systems ( suitable for on receipt testing ) . Used to quantify the degree of cure of cured composite resin systems. Investigative tool for materials subject to thermal processes. Capabilities include analysis under nitrogen and helium purging. Microscopy Brunel Microscope BMS Trinocular Zoom with Konica Minolta A2 8Mb Digital Image Capture - x7 to x45 magnification with rheostat lighting with composite specimen preparation facilities. Environmental Conditioning TAS Micro MCLT Environmental Chamber - Capable of conditioning test specimens in controlled temperature and humidity environments up to 70°C and 95% RH . Wet Chemistry / Physical Chemistry Testing Premier Airflow Fume Cabinet. ( 2 m x 0.75 m x 1 m) Carbon filtered extraction and water scrubbed pipe work. Ohaus Laboratory Balance. (resolution 1 mg) Gallenkamp box furnace max temp 1000 ° C) 150 mm x 120 mm x 250 mm Envelope Carbolite Muffle Furnace (max temp 1000 ° C) 200 mm x 100 mm x 350 mm Envelope Gallenkamp Hot Box Oven (max temp 300 ° C) 500 mm x 350 mm x 320 mm working volume Standard Bench Glassware and Reagents Hotplates , Flasks , burettes , pipettes etc. for performing standard physical and wet chemistry tests associated with the on receipt testing of materials (areal weight , resin content , volatile content etc.) process control testing (fibre volume fraction analysis) Paint Finish Analysis Sheen Mandrel Type Bend Tester Compliant with BS EN ISO 1519 (1995) Mandrel sizes range from 1 mm to 32 mm diameter Sheen Cross Hatch Test Scribe Compliant with BS EN ISO 2409 (1992) Quintsonic Paint Thickness Meter NDT based thickness determination. Resolution 0.1 µm Elcometer Paint Thickness Meter Eddy current based thickness determination Elcometer 20° , 60°, 85° Gloss Meter Process Assurance Equipment · FGH Data Logger: 16 Channels Data logger utilizing FGH Data Manger software for conducting thermal uniformity surveys. · FGH Ezekal 4: Thermocouple simulator , monitoring 8 different thermocouple types , used for calibration of process control instrumentation . · FGH Ezecal 6 : Electronic input simulator for measuring vacuum and RTD inputs as well as traditional thermocouple signals . · Climet 500-1: Laser Diffraction Particle Counter - Conduct environmental monitoring (dust/humidity/temperature) of structural bonding clean rooms. Brookhouse Tooling Ltd - Manufacturing Capability The company workshop facilities cover approximately 72,000 square feet and is staffed by a highly motivated skilled personnel, having the ability to manufacture precision tooling ranging from composite drill and rout tools to sophisticated metal CNC machined mould tools, and general jigs / fixtures to major assembly jigs. A dedicated area of 6000 square feet is available for the manufacture of the large assembly jigs and special purpose machinery fully supported with 8 tonne craneage. In addition to the assembly area there are totally segregated areas for welding fabrication (with craneage) and composite layup. Full inspection certification via CMM or Laser Tracking is available as per customer requirements on all completed tools irrespective of size. Design The design office has broad experience, using the latest technology, in the following industries: - Aerospace, automotive, trains, and the European space programme. High profile projects have been diverse, from small drill jigs to spacecraft assembly tooling, also flight simulators and full facsimile cockpit. Significant experience exists on the design of mould tools. CAD Software Catia 6 Seats  V4.2.4 R01 Solids, surfacing and drafting Catia 9 Seats V5.14, 16 & 18 AutoCad 1 Seat R14  Surfacing and drafting AutoCad 3 Seats Lite 98 Drafting only NC Programming Catia  2 Seats V4.2.2 R01 3 Axis Machining and Roughing Catia 1 Seat V5 Manf. 5 Axis Machining and Roughing (NCR & NC3) Data can be accepted in the following formats:- Catia Export Catia Data Copy Catia Models Iges DXF Dwg Euclid Styler On the following media:- 4mm DAT Tape, CD Rom, Email, 31/2" Floppy, FTP. Brookhouse Tooling Ltd - Plant List Production Tooling, Patterns and Moulds Manufacturing Equipment CNC Machines Correa FP40/50 (5 axis) Correa FP40/50 (3 axis) Correa FP40/40 (3 axis) Correa A30/40 (3 axis) Correa A30/30 (3 axis) Bed size 5m x 2.2m x 1.25m Bed size 5m x 2.2m x 1.2m Bed size 4m x 1.5m x 1.2m Bed size 4m x 1.2m x 1m Bed size 3m x 1.2m x 1m 1 off 1 off 1 off 1 off 1 off Bridgeport interact 3 axis Bridgeport interact 3 axis GX series Bed size 0.75m x 0.37m x 0.5m Bed size 1.02m x 0.6m x 0.5m 2 off 1 off Churchill NC Lathe with Fanuc 3T control Bar capacity to 48mm dia 2 off CMM Measuring Equipment Leica LTD500 Laser Tracker   2 off EP Explorer 3000I Portable CMM Envelope size 3.6m variable 1 off 5 Axis Programmable CMM Measuring cap 3.5m x 2.5m x 1.5m 1 off Conventional Machining Huron Universal Milling Machine size 2m x 0.6m 1 off Genevoise Jig Borer size 0.9m x 1.2m 2 off Kearns Horizontal Borer size 1m x 1m x 1.5m 1 off Lindon Jig Borer size 0.75m x 0.4m 1 off Wadkin Pattern Miller with DRO size 1.3m x 1m x 1.5m 1 off Wadkin Routing Machine size 1.5m x 1.7m 1 off Wadkin Pattern Miller size 3m x 1m x 1.5m 1 off Colchester Centre Lathe 2000   3 off Buttler 460 Centre Lathe   1 off Bridgeport Milling Machine   10 off Jones & Shipman Cylindrical Grinder size 150mm x 400mm 1 off Jones & Shipman Surface Grinders   3 off Double Ended Sanders size 750mm dia pad 5 off 300 ton Hydraulic Press with Heated Plinth   1 off 20 ton Hydraulic Press   1 off Bandsaws size various to 750mm throat 8 off Wood Planers size 450mm table 3 off Wood Planers size 250mm dia blade 3 off Spray Booth size 6m x 4m x 3m 1 off Sifco Plating Plant   1 off Jig Borers Hydroptic 7 SIP (extended arms) X1400mm Y 1000mm Z 2000mm 1 off CNC Milling Machines Correa CNC 3 axis X 2000 Y 800 Z 800 1 off XYZ 4000 DPM 3 axis X 1100 Y 535 Z 600 1 off XYZ 4000 2 axis X 1100 Y 535 Z 600 1 off Bridgeport Interact 2/3 axis X 700 Y 370 Z 350 1 off Conventional Milling Machines Huron KU6 DRO X 1500 Y 600 Z 475 2 off CNC Lathes XYZ Proturn 410 Swing 470 B/Centres1250 1 off Bridgeport Easzpath Swing 480 B/Centres 1150 1 off Conventional Lathes Colchester student 1800 Swing 350 B/Centres 1000 1 off Universal Grinder Ribon 800 Swing 300 B/Centres 600 1 off Surface Grinders Jones & Shipman 540 X 540 Y 370 Z 400 2 off Snow Grinder X 750 Y 350 Z 325 1 off Welding Plant Metallic arc   1 off MIG   4 off TIG   1 off Compasitor Stud Welding Machine   1 off 8 Tonne Over-head Crane in Assembly / Fabrication Area   1 off 5 Tonne Over-head Crane in Assembly / Fabrication Area   2 off Category of Approval Machining 1a General machining (metallic-conventional) 1b General machining (non-metallic-conventional) 1c Screw thread-cutting 1j Grinding 1k NC machining Miscellaneous 11t Ground equipment Brookhouse Aerospace Ltd - Plant lists Detail Manufacture & Aerostructure Assemblies John Shaw Rubber Press This is a 3500 tonne rubber press with a bed size of 6ft by 4ft and has the capability of pressing items 8in deep CNC Router The router is a ‘Wadkin’ router, which has a choice of DNC or direct programming. The bed size is 6ft by 4ft with a working envelope of 5ft by 3ft. Programming is carried out using Alphacam with nesting facilities or alternatively we can us a range of customers programs via post processor. To support the programming we have a digitising table with a 3ft by 5ft capability Grinding Master This piece of equipment was purchased to dramatically reduce the number of man-hours used on de-burring post-routed sheet metallic details.  CNC Press Brake – Arnada HFE 100-3 Multi axis down stroking press brake with a loft bed. Guillotine Edward Pearson 8ft guillotine Manufacturing Aids There are a number of various machines and tools associated with metal manipulation to assist our skilled workforce such as Stretcher Shrinker, Rollers / Wheeler, Drills etc. Welding Facilities The company has a number of highly skilled coded welders who have the necessary approvals to carry out high specification TIG & MIG welding and brazing in a range of materials such as: Aluminium, Titanium, Stainless steel, Nimonics and other exotic materials Spot Welding Machine Specific for Titanium, up to 1mm gauge. Chromic, Sulphuric Anodise & Alocrom treatment & Associated Pre & Post Process Our latest investment has been on a fully automated treatments facility. The bath sizes are 8ft by 3ft by 5ft deep and have been designed with input from BAE SYSTEMS. It meets all our customer requirements and has been built to the latest European H&S standards including effluent treatment “Spray Finishing” The company has 2 Eurotecno spray-bake booths that has a 12ft by 12ft internal working area. The humidity and temperature is monitored via a computer data logger with Thermo Couples. Zinc Spraying To support the treatments facilities a zinc spraying facility has been installed which is complemented by two vacuum blasting cabinets, one for Titanium and the other for Aluminium.  Heat treatment Includes: Salt Bath The bath is 5ft by 3ft by 3ft deep which operates from 360°C to 530°C. Precipitation Oven Our precipitation oven has internal measurements of 8ft by 12 ft. Operating from 121°C to 191°C. Stress relieving The maximum temperature in these particular ovens have internal measurements of 18”x18”x35” and 26”X24”x8”, operating from 360°C to 590°C and 30”x21”x12” operating from 750°C to 1100°C. PFD  This work is carried out by our class 2 approval inspection and has become an integral part of our manufacturing process. 3mtr x 3mtr Penetrant and 3mtr x 3mtr Developer with integral Drying Cabinet of 3mtr x 3mtr x 2mtr. Freezer Walk in Freezer. 16ft x 10ft x 7ft, operating at -25°C. Chest Freezers Chest freezers, 6ft x 3ft x 3ft operating at -25°C and one similar size but operating at -40°C. Pressure Test Rig Hydration Booth Pressure Rig, 3ft sq., operates up to 7,500psi. Power Rollers Morgan Rushworth, 5ft width. Wheeling to shape.