Composites Universal Group (CUG) delivers flight-ready composite parts under an AS9100D quality system with full traceability, disciplined process control, and program-grade documentation. Our approach aligns to NADCAP AC7118 composites audit criteria to reduce risk from first article through full-rate production.
Why Quality Control Matters in Composites
In aerospace, reliability isn’t optional. Variability in layup, cure, machining, or bonding can shorten service life or compromise safety. CUG’s quality-control framework stabilizes every variable that affects laminate quality, structural performance, and dimensional accuracy.
What We Control—End to End
1) Incoming Material Verification
- Lot-level inspection of prepregs, cores, adhesives, resins, and fabrics
- Shelf-life, freezer logs, and certificate review (CoC/CoA)
- Controlled kitting with serialized plies and cores
2) Process Planning & Risk Management
- Traveler-level work instructions with hold points and acceptance criteria
- Risk-based controls for special characteristics and key dimensions
- Configuration management to ensure the built part matches the approved design
3) Layup & Cure Discipline
- Environmental controls for humidity/temperature in layup areas
- Vacuum integrity checks and leak-rate documentation
- Autoclave/oven cure profiles recorded (ramp, soak, pressure, time), with calibrated thermocouples and pressure transducers
- Cure verification (resin content, void criteria, hardness checks per spec when required)
4) Secondary Ops, Trim, & Drill
- CNC trim/drill with validated fixtures and verified tool paths
- Foreign Object Debris (FOD) prevention, protected surfaces, and edge-quality checks
5) Bonding & Assembly
- Surface prep verification (abrade/clean/activate as specified)
- Adhesive lot control, mix validation, bondline thickness checks
- Bolted-joint torque verification and fastener traceability as required
Inspection, NDE/NDT, and Testing
Non-Destructive Evaluation (NDE/NDT)
- Ultrasonic Testing (UT): Detects delamination, porosity, and disbonds
- X-ray/Computed Tomography (RT/CT): Visualizes internal structure for complex parts
- Thermography/Shearography (as program-required): Rapid indication of subsurface defects
Note: Per program needs, NDI is performed in-house or via approved aerospace NDI partners; results are linked to part serial/lot.
Dimensional & Geometric Verification
- CMM and laser scanning for complex geometries
- GD&T compliance, SPC on critical features when specified
- First Article Inspection (FAI) packages delivered to customer format
Mechanical & Materials Testing
- Coupon testing (tension, compression, flexure, ILSS, lap shear) where required
- Adhesive/bondline witness panels tied back to the parent lot/part
Data, Traceability & Continuous Improvement
- Digital traveler records and device calibration traceable to standards
- Lot-to-laminate lineage and full material genealogy
- Real-time process monitoring with SPC where value-add
- Closed-loop RCCA (root cause & corrective action) with human-factors consideration
- Supplier quality management and counterfeit-parts prevention practices
Compliance & Audit Readiness
- AS9100D quality management with product safety and risk-based thinking
- NADCAP (AC7118)–aligned composites procedures and objective evidence
- ITAR-aware workflows for controlled programs (when applicable)
What This Means for Your Program
- Performance consistency: Stable fiber volume, cure quality, and bond integrity
- Fewer escapes & rework: Standardized controls reduce variability and defects
- Audit efficiency: AC7118-aligned records accelerate FAI/PPAP and customer audits
- Better schedule & cost control: Predictable yield and fewer deviations
FAQs
What QC methods does CUG use on composite parts?
Incoming material verification, controlled layup/cure with calibrated monitoring, NDE (UT, RT/CT, thermography/shearography as required), CMM/laser metrology, and documented FAI—tied together by AS9100D and AC7118-aligned procedures.
Can CUG provide full documentation for aerospace programs?
Yes. We deliver traveler histories, material certs, calibration records, NDE reports, and FAI packages. Documentation format can follow customer templates.
How does CUG maintain dimensional accuracy on complex parts?
Through validated tooling/fixtures, CNC trim/drill, and CMM or laser-scan inspection with GD&T reporting on key characteristics.
Do you support bonded and bolted assemblies?
Yes. We verify surface prep, bondline thickness, adhesive cure, and torque/fastener controls per specification, with traceable records.
