Process safety and performance

Dispensing technology for composite manufacturing

Advanced systems for interior and exterior aircraft component production

DOPAG has decades of experience in the production of interiors and exteriors in the aerospace industry. In particular, DOPAG offers high-quality solutions for the production of fiber composite components: For the highly complex lightweight materials, DOPAG developed special equipment that ensures precise metering and mixing and meets the needs of increasing automation.

For many years now, the aerospace industry has been a quickly growing market on an international basis. The number of airliners, for instance, that amounts to 15,000 planes today, will more than double by the year 2030. This means the production rates must be increased significantly to be able to meet the strongly growing demand. Well-known manufacturers are working on increasing their production output for their top sellers from values that currently are far below 50 units to more than 60 airplanes per month. So at least two new planes per day are planned to leave the workshop in the near future.

Cost savings in the course of the production and the pursued reduction of the greenhouse effect are additional challenges. This comprises both the optimization of the jet engines and new and especially light materials such as fiber-reinforced composites that currently make up approximately 50 per cent of the materials used. Higher cost efficiency can only be achieved with automated manufacturing processes with systems that can operate at high speed and with excellent reliability and deliver a high-quality result. That means the portion of manual work that currently is still rather high must be automated in the long run.

Intelligent solutions by DOPAG
As the market leader, DOPAG possesses technologies for high-precision mixing and dosing with assured quality for all stated procedures and supplies the largest sub-contractors of the aerospace industry with systems. Based on many years of experience in processing epoxy resins and complex materials such as polysulfides used for sealing aircraft fuel tanks and outer skins, systems have been developed that are used all over the world and that meet the demand for increasing automation. Especially in view of the new trends towards the increased production of composite fiber components, DOPAG offers technically advanced solutions that ensure precise mixing and metering of the materials.

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Special metering system for the homogeneous, automated filling of honeycomb panels

Honeycomb panels are primarily used in aircraft interiors, such as in toilet walls and side panels, kitchen structures and floor panels. Honeycomb panels, or sandwich panels with a honeycomb core, are first produced for this purpose. To ensure high stability of the honeycomb structure, they are filled with low-density materials. The DOPAG metering system coredis enables the automated filling of honeycomb cores by means of a robot and portal system.

Reference projects


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All DOPAG articles at a glance:
  1. Metering mixing and applying thermally conductive silicone material

    The vectomix TC metering and mixing system from DOPAG processes thermally conductive materials precisely and cleanly. This application shows the processing of Wacker Semicosil 9672.

  2. Dispensing of liquid silicone rubber (LSR) in medical technology, food industry and e-mobility

    Particularly strict conditions apply to production in the medical technology and food industries. A special configuration from DOPAG enables the use of the dispensing system in the clean room.

  3. Bonding and sealing in aircraft production

    The metering and mixing system volumix provides a smart solution for filling cartridges with adhesives and sealants in aircraft production.

  4. Honeycomb potting of sandwich panels

    With the dispensing system coredis, the honeycomb core of sandwich panels, which are used for the interior of aircraft, could be filled homogeneously.

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Composite processing: Honeycomb Potting / Core Filling in aerospace industry

Bonding and sealing is becoming an increasingly popular method of joining components without screws. With DOPAG systems, applications can be realized reliable and precise.

  1. compomix


    The compomix DI was developed for dispensing epoxy and PU in infusion processes in the production of rotor blades.

  2. eldomix


    The eldomix 100/600 range of systems are compact, solvent free, gear pump driven metering and mixing systems.

DOPAG offers reliable solutions for the manufacture of fibre composite components, for example RTM, Filament Winding, Infusion, Pultrusion, etc.

  1. compomix


    The compomix DI was developed for dispensing epoxy and PU in infusion processes in the production of rotor blades.

  2. coredis


    Coredis is used for the processing of especially light low density 1K epoxies filled with micro hollow spheres.

  3. eldomix


    The eldomix 100/600 range of systems are compact, solvent free, gear pump driven metering and mixing systems.

  4. gelcomix


    The gelcomix is a gelcoat application system, especially developed for surface production of rotorblades and composite parts.

  5. vectomix


    Vectomix is used to handle multi component materials. Due to its compatibility and modularity, two vectodis single component piston metering with equal or different sizes are used.