Our Process

Introduction

Before delivery of the parts to the customer, the company is following a systematic process. Based on the customer’s requirements DNK supports at designing and validating the model. According to the required geometry the tools and materials are prepared. After the manufacturing, DNK once again validates the product quality with regard to the requirements in order to ensure that every product is manufactured as designed.

Introduction

Before delivery of the parts to the customer, the company is following a systematical process. Based on the customer’s requirements, DNK is supporting to design and to validate the model. Based on the geometry, the tools and the material will be prepared, and after the manufacturing, DNK is checking the product quality towards the requirements again to ensure that every product is manufactured as designed.

Design & Validation Process

In order to guarantee highest safety of our products, we design and plan our composite parts in line with the customer’s requirements, as well as with the standards directed by the aviation authorities. In practice, this means that we achieve the most suitable geometry for the product which is optimally balanced with regard to minimum weight as well as stress requirements while also easy to install and maintain.

 

After receiving the geometric specifications from our clients, DNK’s design and engineering team at first checks the manufacturing feasibility. The design team then transforms and adapts the geometry into a suitable carbon fiber model. Based on the stress requirements and material selection the FEA analysis supports at deciding on a design that is well-balanced concerning the static requirements at optimized weight. The feedback from the DNK team is supposed to help the customer to find the appropriate product design.

 

Based on the final product design the DNK design team develops the mold design and ply book in order to launch the manufacturing process.

Design & Validation Process

To guarantee the highest safety of our products, we design and plan our composite parts in line with the customer’s requirements, as well as with the standards directed by the aviation authorities. In practice, this means that we are achieving the most suitable geometry for the product that is best balanced between the low-weight and stress requirements, and easy to install and to maintain.

 

After receiving the geometry specifications from our clients, DNK’s design and engineering team first check the manufacturing feasibility. Then the design team then transforms and adapts the geometry into a suitable carbon-fiber model. Based on the stress requirements and material selection, the FEA analysis supports to decide a design, that is balanced perfectly to fulfil the static requirements with optimized weight. The feedback from the DNK team may help the customer to find the perfect product design.

 

With ideal final product design, the DNK design team creates the mound design and the apply book for the launch of the manufacturing process.

Tooling Process

The required molds are manufactured at our factory with the help of 3D printing technology and highly accurate CNC machines which allow us to minimize quality risks and to react fast and flexibly on customers’ requirements. Our steel molds are the best choice to produce constant quality also at large quantities. Furthermore, having the machines in-house, we are also able to efficiently apply corrections or changes to the tools.

Tooling Process

We manufacture the needed molds in our facility with the help of 3D printing technology and our highly accurate CNC machines, which allow us to minimize quality risks and to react fast and agile on customer’s requirements. Our steel molds are the best choice to produce repeatable quality, even in high volumes. With the machines in-house, we efficiently can perform changes and corrections on the tools. That allows us to react fast and flexible on customer requirements and to control our quality.

Material Handling And Manufacturing

Proper material handling is essential in order to produce flawless products. This includes thorough documentation, supplier selection, material selection, material inspection and adequate storage.

 

We select and audit our material suppliers conscientiously in order to ensure a stable process. Moreover, we independently conduct substantial tests beyond the suppliers’ test reports. Our materials are stored and monitored in dedicated rooms that provide the required climatic conditions.

 

The crucial process step of manual lay-up of the carbon fiber layers takes place in controlled clean rooms to protect the product from any contamination and to assure that the raw materials are used within their specifications. The DNK workers are well-trained and wearing suitable working gear including gloves.

 

Apart from carbon fiber, DNK is experienced in using other composites such as glass fiber as well as core systems like foams, honeycomb, and releasable cores that can be combined with carbon fiber.

 

In order to ensure stable product quality all our machines and instruments are being calibrated and checked on a yearly basis. The instructions of the design department are followed step by step. Moreover, every product is tracked throughout the manufacturing process.

Material Handling And Manufacturing

Proper material handling is necessary to produce flawless products. This embraces the complete documentation, supplier selection, the material selection, the material inspection and its storage.

 

We select and audit our material suppliers and perform to the supplier’s test reports independently substantial tests to ensure a stable process. Our material is stored and surveilled in dedicated rooms that provide the right temperature.

 

The manual lay-up of the carbon material is crucial and takes place in controlled clean rooms to protect the product against any material contamination and to assure that the raw materials are used within their specifications. The DNK workers are well trained and are wearing suitable clothing such as gloves to protect the products.

 

Apart from carbon fiber, DNK is further experienced in using a different kind of materials such as glass fiber and core systems like foam, honeycomb and releasable cores that minimize the weight of the product.

 

To ensure stable product quality, all our machines and instruments are being calibrated and checked on a yearly basis. DNK follows step-by-step the instructions from the design department. To surveil our quality, DNK tracks every product going through the manufacturing process.

Final Test and Conformity Check

When manufacturing, we inspect the first sample (FAI) for compliance with the engineering requirements and design. We use non-destructive (NDT) as well as destructive (DT) methods to guarantee that the manufactured part is fulfilling the requirements.

 

Quality gates, quality control and adequate employee training are standard success criteria in our manufacturing process. To increase our level of quality continuously, we measure, label, and track every product coming out of our manufacturing facilities. This allows us to learn which procedures perform best and to provide the best support to our customers.

 

At the end of the manufacturing process, the products are tested with our professional and accurate in-house testing equipment and with the support of professional testing agencies like SGS as well as laboratories of local universities.

Final Test and Conformity Check

When manufacturing, we inspect the first sample (First article inspection) for compliance with the engineering requirements and design. We use NDT and DT methods to guarantee that the manufactured part is fulfilling the requirements.

 

Quality gates, quality control and adequate employee training are standard success criteria in our manufacturing process. To increase our level of quality continuously, we measure, label and track every product coming out of our manufacturing facilities. That allows us to learn which procedures performed the best and to provide the best support to our customers.

 

At the end of the manufacturing process, the products are tested with our professional and accurate in-house testing equipment and by the support of professional testing agencies like SGS and the laboratories of local universities.

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