Composite materials have changed how aircraft are built. Many modern aircraft use carbon fibre and glass fibre reinforced plastics in control surfaces, fairings, floors, radomes and even major structures. Composites are popular because they are strong for their weight, resist corrosion and can be shaped into smooth aerodynamic forms.

How composites are made

A composite combines fibres, which carry the load, with a resin matrix that holds the fibres together and transfers load between them. Layers of fibre called plies are stacked in different directions to give strength where it is needed. Sandwich structures place a lightweight honeycomb or foam core between two thin skins to create stiff, light panels.

Typical damage

Composites do not dent like metal. Impact damage can hide under an undamaged-looking surface as delamination, where plies separate, or disbonding, where a skin separates from its core. Moisture can enter damaged areas, and heat or lightning strikes can also cause damage.

Inspection and repair

Engineers start with careful visual inspection, then use tap testing and non-destructive methods such as ultrasonic inspection to find hidden damage. Repairs follow the structural repair manual exactly: removing damaged material, preparing the surface, laying up new plies in the right orientation and curing under controlled temperature and pressure.

Learning it at Redwings

Composites are part of Module 6 Materials and Hardware, and repair practices are covered in Module 7. Faculty connect these topics with examples from real maintenance so that students understand both the theory and the care needed when working on composite structures.