Structures (Munitions, Reflectors, Precision Structures & More)

Composites offer a significant advantage in structural technologies by providing a combination of strength, lightness, and design flexibility that is unmatched by traditional materials. These properties contribute to improved performance, survivability, and cost-effectiveness.

Munitions

Our defense infrastructure depends on innovation to keep our nation safe. Examples of composite applications in missiles:

Rocket motor cases, nozzles, control surfaces, fuselages: Lightweight and strong, able to withstand high pressures and temperatures.
Nozzles: Heat-resistant and durable for efficient exhaust gas expansion.
Control surfaces: Precise and lightweight for accurate maneuvering.
Fuselage and wings: Strong, lightweight, and aerodynamic for optimal flight performance.

Show here is a carbon fiber composite shell that is for a low-drag general-purpose, high-explosive fragmentation bomb. The carbon fiber composite shell achieves three times less collateral damage by keeping the blast radius tight. The carbon fiber disintegrates upon detonation, minimizing fragmentation and decreasing damage to nearby structures.

Precision Reflectors, Crafted to Perfection

Our team specializes in designing and fabricating high-precision reflectors and light-weight associated structure that meet the most stringent surface profile, finish, and weight requirements. The quality of a reflector is directly tied to its accuracy in surface precision, stiffness and surface electrical continuity. Our understanding of these principles is critical for ensuring optimal performance in applications ranging from ground-based telescopes to space-borne antennas.

With our expertise in composite materials and advanced manufacturing techniques, we have successfully delivered a wide range of reflector solutions, including:

Single-part reflectors: For applications demanding maximum structural integrity and minimal assembly.
Deployable reflectors: Ideal for space-limited environments or missions requiring compact stowage.
Ground-based reflectors: Designed for terrestrial applications such as radio astronomy and satellite communication.
Flight-worthy and space-worthy reflectors: Meeting the rigorous standards of aerospace and space exploration.

The communications reflector show here was designed to be deformable in order to tune the signal as necessary. Read our case study Satellite Datalink 2.4 Meter Dimensionally Tunable Reflector.

Dimensionally tunable reflector. Reflector dish with rigid back-structure with adjustment points.

Precision and High-Accuracy Structures

We will take our knowledge of materials to make structures that meet stringent technical requirements, including near zero CTE or high stiffness, and do it with commercial sensibilities, finding innovative solutions to tighten schedule and budget, while lowering risk.

The hardware shown here is a high precision tool you can read about in our case study Thirty Meter Telescope Laser Tracker Metrology Fixture.

Fairing aerostructure. Curved white shape with drill holes along the edges and metallic inserts around the central hole.

Aerostructures and Complex Shapes

For all of the shapes that make up aircraft, from fuselages to floorboards, from nozzles to wings, composites bring many benefits to the table. Our team can help with

From design to fabrication
Vibration analysis
Tight profile tolerance
Outgassing constraints
Precision assembly
Specialty coatings
Load testing

RWC also manufactures Aircraft replacement parts. Read more in our Aircraft section.