As specialists in a myriad of technical systems, including preforming, resin transfer infusion, and reticulation, PAC Composites has a rich history of serving diverse sectors such as aerospace, automotive, marine, composites, and plastics. One of their standout products is the Preformer, or Hot Drape Former, which is renowned for its efficiency and versatility. For this particular project, PAC Composites was tasked with designing, manufacturing, and installing an 18m x 4m Preformer. This vacuum former, equipped with Quartz Infrared Technology, is capable of crafting entire aeroplane wings.

The wings produced are the first certified commercial aircraft wings made using Resin Transfer Infusion (RTI). Unlike other methods that rely on pre-impregnated carbon fibre and necessitate intensive refrigeration, the RTI process is more energy-conservative, uses fewer parts, and results in a lighter wing. This innovative approach not only reduces the environmental footprint of commercial jets but also marks the inaugural use of a Preformer to craft entire wing skins outside of an autoclave.

Key features of the Preformer technology include:

• Flexible Zoning: Enables the creation of any part of any size, optimising production time and energy costs.
• SMART Software: Developed by PAC Group, this software learns production profiles, minimises wastage, and can self-diagnose operational issues.
• Fully Bespoke Design: Every element of the Preformer can be customised based on client specifications.
• Patented Technology: PAC Group boasts 42 patents related to the Preformer’s hardware and software.

The installation process was intricate, with PAC Composites setting up the machine in an operational clean room. An environmental booth was constructed to safeguard the facility’s conditions, ensuring consistent temperature and humidity levels. Furthermore, all process parameters are meticulously logged for each batch, ensuring full NADCAP traceability.