Aerospace Manufacturing: Composite Material Cutting and Bonding Processes and Using LEV.

Composite materials have become indispensable in aerospace manufacturing due to their lightweight, high-strength, and corrosion-resistant properties. These materials enable manufacturers to produce more efficient aircraft that meet stringent performance and environmental standards. However, working with composites also presents unique health and safety challenges, particularly during cutting and bonding processes. Implementing adequate Local Exhaust Ventilation (LEV) systems is critical for ensuring a safe and compliant work environment.

Understanding Composite Material Hazards

Composite materials, such as carbon fibre-reinforced polymers (CFRP) and glass fibre-reinforced polymers (GFRP), are extensively used in aerospace structures. While these materials offer exceptional benefits, the processes involved in shaping and assembling them can release hazardous substances, including:

1. Dust and Particulates: Cutting, drilling, and sanding composites generate fine airborne fibres and dust. These particles can be inhaled, leading to respiratory issues such as irritation, fibrosis, or long-term lung damage.

   
   

2. Chemical Fumes: Bonding processes often involve adhesives and resins that release volatile organic compounds (VOCs) and other hazardous fumes. Prolonged exposure can cause headaches, dizziness, and more severe health effects.

   
   

3. Thermal Decomposition By-products: High-temperature processes, such as laser cutting or curing, can release toxic gases and vapours.

   
   

The Role of LEV in Aerospace Manufacturing

Local Exhaust Ventilation (LEV) systems are designed to capture and remove airborne contaminants at their source, preventing their dispersion into the workplace. In aerospace manufacturing, LEV is pivotal in safeguarding workers and maintaining compliance with safety regulations.

Key Applications of LEV in Composite Processes

1. Cutting and Drilling

   • Challenges: Composite materials produce fine, lightweight dust suspended in the air for extended periods.

   • LEV Solutions:

     • Hood systems are positioned directly at the cutting or drilling site.

     • Downdraft tables are equipped with integrated suction.

     • Portable extraction units for flexibility in dynamic workspaces.

       
       

2. Sanding and Finishing

   • Challenges: High-volume dust generation during surface preparation.

   • LEV Solutions:

     • Hand tools with built-in extraction capabilities.

     • Centralized duct systems to ensure consistent dust capture.

       
       

3. Adhesive Bonding

   • Release of VOCs and solvent vapours during adhesive application and curing.

   • LEV Solutions:

     • Enclosed are workstations with ventilation to contain and extract fumes.

     • Capture hoods for open-area bonding processes.

       
       

4. Thermal Processes

   • Challenges: High-temperature cutting and curing can emit toxic gases.

   • LEV Solutions:

     • High-efficiency filtration systems for capturing gaseous emissions.

     • Heat-resistant ductwork and exhaust fans.

       
       

Benefits of LEV in Aerospace Manufacturing

1. Worker Safety: Protects employees from inhaling harmful substances, reducing the risk of occupational illnesses.

   
   

2. Regulatory Compliance: Meets health and safety standards such as OSHA, COSHH, and EU directives.

   
   

3. Enhanced Productivity: Creates a clean and safe workspace, minimizing downtime and improving efficiency.

   
   

4. Environmental Responsibility: Reduces emissions of hazardous substances into the environment.

   
   

Best Practices for Implementing LEV

• Risk Assessment: Conduct a thorough evaluation of processes to identify hazardous points and determine appropriate LEV solutions.

  
  

• Custom Design: We tailor LEV systems to meet the specific needs of composite manufacturing, considering factors such as material type, equipment layout, and process scale.

  
  

• Regular Maintenance: Perform routine inspections and maintenance to ensure LEV systems operate efficiently.

  
  

• Training and Awareness: Educate workers on the importance of LEV and how to use systems effectively.

  
  

Conclusion

As aerospace manufacturing continues to evolve, composite materials will remain a cornerstone of innovation. However, the health and safety challenges of these advanced materials cannot be overlooked. By integrating robust LEV systems into cutting and bonding processes, aerospace manufacturers can protect their workforce, ensure regulatory compliance, and foster sustainable practices. Investing in effective LEV solutions is not just a regulatory requirement—it’s a commitment to excellence and responsibility in aerospace manufacturing.