AirCor™ molded-to-shape hollow structures
Structures Solutions

Hollow aerospace structural parts
made with AirCor™ technology
Ducommun's AirCor™ system is a unique, patented part of the Ducommun Foam Matrix technology family in that it can produce large hollow composite structures in a single manufacturing step. These structures are typical of aircraft wing or control surface structures and can also be used to produce "wet wings" with internal fuel tanks, or dry equipment bays.

Similar to other Ducommun Foam Matrix Core System™ (FMC) technologies, AirCor structures are constructed using composite materials and foam cores. Unlike many other Ducommun FMC structures, the foam core is completely removed after cure, using proprietary methods, leaving a cavity within the structure. Ducommun AirCor technology structures can integrate pressure fittings, attachments and mechanical fittings into the structure, eliminating secondary assembly steps. This is an ideal method for making a single-piece composite fuel tank in the shape of a wing or typical aircraft structure.


An assortment of AirCor™ technology components
Ducommun's AirCor system allows thick structures without faying surface bonds. Initial indications show that this construction method is more durable, lighter weight and significantly lower cost than conventional composite or metallic structures.

AirCor technology can be used to produce parts with both filled and unfilled sections. For example, single piece UAV wings have been produced with foam filled leading and trailing edges and a hollow air core center section.

For a more detailed description of how Ducommun's Foam Matrix Core System technologies achieve these benefits, click here.


AirCor and Foam Matrix Core System are trademarks of Ducommun Incorporated.

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