Excellent strength to weight. An all-purpose grade used in multiple industries
High-temperature resistant core suitable for prepreg applications
High-performance core for extremely demanding applications such as fast marine hulls
Superior strength to weight. Used in multiple industries, including wind and marine
A PET core with excellent FST properties used in transport and construction industries
A recyclable core material used in a variety of applications such as domes and claddings
Well-suited for use as local inserts in the way of fittings, either tapped or bolted through
A thermoplastic core material designed to increase performance and decrease weight
An aerospace core available with comprehensive quality documentation and traceability
A sandwich core with excellent FST properties, suitable in commercial aircrafts interiors
Core material for subsea applications, used from sea level to 700 meters depth
A deep-water subsea syntactic foam used for depths from 700 to 10,000 meters
A core with excellent insulation properties, for low and cryogenic temperatures
Used in marine and wind applications in combination with foam
A selection of the most widely used and preferred finishing options
The flight simulation industry demands light, mobile and structurally resistant components of precise dimensions that resist induced vibrations. Weight reduction is critical as it provides improved modal performance as well as a reduced life cycle cost when running the simulator on the motion system. Using high-performance sandwich core materials addresses both these issues.
Leading simulation systems integrator L-3 Link Simulation & Training’s Reality 7 flight simulators undergo a lot of shake and rattle as they perform many dynamic movements during flight. They must also correctly simulate the experience of turbulence. Moreover, a trainee pilot shouldn’t be disturbed by any external noises, which puts extra demands on the building material.
Four party collaborative design process
UK’s Composite Moulding Specialist, Norco GRP Limited, began working with L-3 in 2011. The objective was to develop a new design concept for the Reality 7 flight simulator, keeping the aesthetics as close as possible to the original, whilst lowering the production cost. Following an extensive four party collaborative design stage, involving Engenuity, Rockwell Collins and L-3, Norco was awarded the manufacture contract in October 2012.
Divinycell for exceptional weight saving
The primary task for Norco was to develop the main mirror bowl, spanning 5 meters and supporting the entire visual system. After more than ten years of cooperation with Diab, the choice of core material was agreed and Diab provided Norco with a pre-cut Divinycell Kit that could be fitted directly into the mould, saving valuable production time and material waste. Using a combination of UD carbon fiber and glass fiber prepreg, combined with Diab’s lightweight foam core, Norco was able to save around 300kg, allowing the canopy to weigh in at just 135 kg.
Kit solutions add extra value
“We have worked in partnership with Norco for many years”, says Keith Evans, Managing Director at Diab UK. “Our cooperation began, as usual, with on-site technical advice and project discussions with support and recommendations. The fact that we back up our product offering with cost effective kit solutions and value-added services, adds extra value to our customers.”
Overall, the Reality 7 simulator’s design development process to prototype took 18 months. Norco delivered the first Reality 7 simulator to L-3 in March 2013 and it is currently working on unit number four of a contract for 24 units in total.
For more information, please visit www.norco.co.uk and www.link.com
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Diab has been at the leading edge of composite core material development for over sixty years, supplying a wide range of markets including marine, wind energy, transport, aerospace and industry.
Diab is wholly owned by Ratos.
Diab International AB
Drottninggatan 7, 5th floor
252 21 Helsingborg, Sweden
312 22 LAHOLM, Sweden
Tel +46 (0) 430 163 00