Built in Al Ain in 2009, and expanded in 2015, the facility has 31,500 m2 of production floor space.
Focused on build-to-print production of primary and secondary aerostructures using advanced composite materials.
The qualified facility in July 2010, current qualifications: NADCAP, EN9100, and is qualified by the Original Equipment Manufacturer (OEMs).
Qualifications include NADCAP – Composites, NADCAP-NDT, NADCAP – Chemical Processing, EN9100:2016, ISO 14001:2015, and OHSAS 18001:2007.
Strata’s laboratory provides mechanical and physical testing of all critical materials which enter the production process. This laboratory is qualified by both Strata’s key customers as well as international regulatory authorities to ensure that materials such as glass or carbon fiber are suitable for use.
The Composite Honeycomb Machining area is responsible for the machining of all honeycomb cores used in production. The purpose of a core in the manufacturing process is to increase the laminate’s stiffness by effectively ‘thickening’ it with a low-density material. This provides the products with a dramatic increase in sturdiness whilst adding very little weight, this being a primary objective in the aerospace industry.
Strata has invested in state-of-art Contamination Controlled Area, or often referred to as a ‘Clean Room’. The Strata CCA is 4000 sqm and is designed to ISO Class 8 specifications meaning the air is filtered 10 times per hour whilst temperature, relative humidity and dust particle count are tightly controlled and monitored 24/7.
Prepreg materials (glass and carbon fiber) are cut to size by Strata’s three ply-cutting machines, to the engineering drawings with an accuracy of +/- 1mm. These plays are then delivered to the lay-up stations where a laser projection system shows the Aero-structure Technicians the precise location of where the ply is to be laid inside the mold tool. This process is repeated several times with several compactions using vacuum pressure to ensure that there is no air between the different layers.
On completion of the lay-up process, the part is again placed under vacuum pressure and prepared for the autoclave cure cycle. The vacuum bag is checked for leaks before leaving the cleanroom and must not show loss of pressure more than 0.2 bar in 5 minutes.
Autoclaves use a very precise combination of heat, pressure, and vacuum to transform the prepreg materials into very strong and sturdy parts. These machines use Nitrogen as it is an inert gas therefore not promoting combustion within the Autoclave cure process. During the curing process, the pressure of up to 10 bars is applied under a temperature ramp-up of up to 250 degrees centigrade for approximately six hours.
Strata’s four 5-Axis CNC Machines (Computer Numerical Control) is responsible for the trimming of all products down to the specifications called for by the customer. These machines are capable of cutting up to 65 meters per minute and are accurate to 0.02mm, the average thickness of human hair.
Non-Destructive Testing (NDT) is used to confirm the Quality and conformity of the bonded products produced in the CCA. Methods in use include A-Scan, 3 axis C-Scan, 10 Axis C scan, X-Ray, and manual tap testing. In this process Strata can determine the quality of the products, meeting the standards set by the customers’ specifications.
The paint scheme applied on the aircraft parts is not just a statement of our customers’ brand, it also protects the product from the elements in vastly varying environments which aircraft must operate.
Strata’s state-of-the-art paint facilities are responsible for the application of primer, anti-static/lighting strike protection, as well as the high finish final paint.
The Assembly Area is where all aircraft parts undergo the final fittings of metallic parts, seals and any other sub-assembly. The Technicians here are responsible for the drilling, assembling and interchangeability checks for all products, thus ensuring that the product will fit onto the aircraft.