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.
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.
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.
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.
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.