Modern aircraft rely on composite materials for their strength, light weight, and resistance to corrosion. But when damage occurs—whether from bird strikes, hangar rash, or simple wear and tear—the repair process requires a very different approach than working with metal.
Whether you’re an aircraft owner making decisions about a repair, or a technician looking to sharpen your skills, understanding the basics of composite repair can save time, money, and headaches down the line.
1. Not All Damage Is Created Equal
Composite damage can range from visible cracks to hidden delamination that can’t be seen from the surface. Early detection is key—technicians often use tap tests, ultrasound, or thermography to locate internal issues before they spread.
2. Repairs Require Specialized Skills and Equipment
Composite repairs aren’t just “patch and go.” They require precise temperature control, curing processes, and the right resin systems to match the original structure’s properties. This is why choosing an FAA-certified shop with composite expertise matters.
3. OEM vs. Field Repairs
While Original Equipment Manufacturer (OEM) repairs are sometimes necessary, many composite issues can be resolved more quickly and cost-effectively in the field—provided the shop has the proper tooling, materials, and approval.
4. Long-Term Benefits of Doing It Right
A properly executed composite repair will restore the part’s original strength and aerodynamic profile. Cutting corners, on the other hand, can lead to structural compromise, reduced performance, and expensive rework later.
5. Preventing Future Damage
Simple steps like hangar storage, using wing and tail covers, and being mindful of ground handling can significantly extend the life of composite structures.
Final Takeaway:
Composite repairs are part science, part art. Partnering with an experienced, certified repair station ensures your aircraft gets back in the air safely, quickly, and in peak condition.
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