Aircraft Structures and Equipment

Aircraft Structures Equipment

Lightweight composites provide a solution to complex engineering problems and bring significant benefits to both manufacturers and equipment operators. Lighter and also more flexible than metallic materials, composites can be moulded into more complex shapes cost-effectively, and because they are non-corrosive, the through-life cost is also reduced.

Marshall has over 40 years’ experience in providing complete design, certification, manufacture and through-life support of composite aircraft structures and equipment, including unmanned aerial vehicles and aircraft helmets. Our design and processing engineers provide solutions to even the most demanding of requirements and, thanks to our in-house manufacturing capabilities, we are able to produce these structures to the highest standards from a wide variety of composite processing techniques. We are also able to call upon our extensive experience in aircraft integration to fully install and integrate the system or structure onto the aircraft.

Because we offer this complete solution without the need for additional contractors, we can manage the whole process and significantly reduce risk and cost to the programme. We are uniquely well-placed in the aerospace and defence market to turn the customer’s vision from concept into reality.

Over the last 40 years, we have worked on a variety of projects ranging from high temperature air conditioning ducting to auxiliary fuel tanks.

Eurofighter Typhoon Helmet

Eurofighter Typhoon Helmet

Manufactured for BAE Systems, the Eurofighter Typhoon helmet leads the market with the most advanced fast jet helmet shell in the world, and is the first composite helmet to pass high-speed ejection tests. The shell is a prime example of Marshall repeatable production, manufactured to the millimetric tolerances necessary to provide an accurate interface between the helmet’s electronics and aircraft’s sensors. The carbon construction benefits from low thermal expansion and is incredibly stiff, eliminating visor distortion and providing exceptional protection. The quality and integrity of the helmet structure is maximised thanks to our clean room manufacturing environment and autoclaves.

Marshall has also produced composite helmet shells for the JAS39 Gripen, Hawk trainer and helicopters including the AH1Z Viper and Eurocopter Tiger.

C-130 Cockpit Trim Panels

We manufacture flight deck trim panels for the Lockheed Martin C-130J aircraft, utilising our environmentally-controlled clean rooms and autoclave cure to ensure the highest standard composite manufacture. The panel is a phenolic glass fibre prepreg with a Nomex sandwich panel core.

Falcon 7X Honeywell Air Conditioning Unit

Falcon 7x Honeywell Air Conditioning Unit

The Honeywell air conditioning system on the Dassault Falcon 7X business jet has a composite air intake and plenum chamber made from a flame-retardant high-temperature carbon cyanate ester material, meaning the structure is much lighter than metallic equivalents, greatly reducing the weight of the overall conditioning system.

Dash 8 Engine Nose Cone

The world’s first composite engine nose cone, this structure can withstand a bird strike at 350mph and the effects of a lightning strike. Thanks to its composite construction, the nose cone is much lighter and relatively cheaper to produce than metallic equivalents.

Maritime Sonobuoy Carousel Dispensers

EH101 Sonobuoy Carousel Dispenser

We have designed and manufactured composite sonobuoy carousel dispensers which consist of filament wound body tubes with metallic assemblies. These have been qualified for use on AgustaWestland EH101 and Sikorsky S92 helicopters and also certified for use on the P-3 Orion maritime patrol aircraft (and formerly Nimrod).

With this breadth of experience and capability, our customers can be sure that Marshall will deliver the right composite solution for their needs, manufactured to the highest standard to ensure maximum performance from the aircraft and equipment.