Entering the Aviation Industry
Diehl Aviation – the aerospace division of the Diehl Group – is one of the world’s most significant suppliers of passenger-cabin systems for commercial aircraft. The company supplies complete cabin solutions to Airbus, Boeing and other major manufacturers, from overhead bins to lighting systems. Carbon Composites Ltd. began its collaboration with Diehl Aviation in 2015, when the company planned a Hungarian capacity expansion for certain composite-part tooling and production.
The aviation industry imposes some of the strictest quality requirements of any sector, where every single component must comply with certifications and standards prescribed by aviation authorities. Carbon Composites already held EN 9100 certification – the equivalent of the AS9100D international aerospace standard – before the collaboration began, qualifying the company for the manufacture of aircraft components.
Project Background & Challenges
Diehl Aviation continuously seeks innovative supplier partners that can meet the highest quality expectations while offering competitive pricing and flexible capacity. Carbon Composites, as a Central-European manufacturer, proved an ideal partner – the geographical proximity enables fast response times and efficient logistics to European assembly plants.
At the project’s outset, the greatest challenge was meeting aviation-industry documentation requirements. Every manufacturing process, material and test must be documented in detail, ensuring full traceability from raw material to finished part. Carbon Composites established a dedicated quality-assurance team to support the project, working exclusively on aviation orders.
Manufacturing Technology & Processes
The cabin components are produced using prepreg technology, the most widely used method for manufacturing aerospace composite parts. Prepreg materials are pre-impregnated carbon-fibre or glass-fibre fabrics in which the resin is present in a precise quantity and uniform distribution. This ensures reproducible quality, high fibre volume fraction and therefore excellent mechanical properties.
The tooling required for production is made in-house: high-temperature-resistant CFRP (carbon-fibre-reinforced) layup tools can reproduce complex 3D geometries, complete with integrated metal locating inserts and fastening elements. Thermocouple temperature sensors are built into the tool backs, providing real-time monitoring of cure-temperature uniformity during autoclave cycles.
Layup is carried out in a clean-room environment where temperature and humidity are continuously controlled. After layup the parts enter the autoclave for curing at high pressure and temperature. Autoclave cycle parameters are precisely defined and documented, ensuring consistent production quality.
Finished parts undergo CNC machining to achieve precise contours and mating surfaces. After machining, surface treatment and painting follow, meeting aviation flammability and smoke-generation regulations. Every part goes through final inspection including dimensional measurement, visual inspection and, where required, non-destructive testing.
Manufactured Components
Carbon Composites produces numerous cabin components for Diehl Aviation. Structural elements of overhead bins are among the key products – these form the framework and cladding of the luggage compartments. These elements serve not only an aesthetic but also a structural function, as they must safely withstand significant loads.
Sidewall panels form the interior cladding of the passenger cabin, serving both a decorative and an acoustic-insulation role. Ceiling panels and lighting-system cover elements are also among the manufactured products. Every panel surface complies with FAR 25.853 and CS 25.853 flammability standards.
Quality Assurance & Certifications
In aerospace manufacturing, quality assurance is a top priority. Carbon Composites’ AS9100D certification ensures that the company’s quality management system meets the special requirements of the aerospace industry. The EASA Part 21G production approval enables direct supply of aircraft components to major OEMs.
Every production batch has detailed documentation containing material certificates, process parameters, measurement reports and final-inspection results. Traceability is ensured from raw-material batch numbers right through to installation. The non-conforming product management and corrective action system guarantees continuous improvement.
Results & Future Plans
The collaboration with Diehl Aviation represents a significant milestone in Carbon Composites’ development. Aviation projects bring not only prestige but also drive the establishment of the highest-level manufacturing culture and quality-assurance systems, which positively affects all of the company’s activities.
Within the project, more than 500 different parts have been manufactured to date, all of which have successfully passed Diehl Aviation’s and the end users’ quality audits. Capacity is continuously expanding, and the transfer of additional product groups is planned for the coming years. Carbon Composites’ goal is to contribute as a reliable, long-term partner to the success of Diehl Aviation and thereby the aerospace industry.