Elbit Systems Ltd. offers advanced integral composite aerostructures that significantly cut costs and shorten lead time.

Following intensive development efforts, Elbit Systems - Cyclone achieved a unique, highly advanced integral composite structural design that is manufactured with "zero fasteners" in a genuine "one-shot" processing. Elbit Systems' composite structures are extremely lightweight, stronger and cost effective, while enhancing overall flight safety and aircraft structural performance.

The new technology "fastener free" composite door design is manufactured in "one shot" with the use of integral composite fittings, a sophisticated and highly efficient structural design that reduces operational and manufacturing costs. Cyclone's innovative design utilizes geometrically-locked composite fittings that are embedded between the main frame layers, co-bonded and mechanically locked to the main frame beams with no fasteners.

The all-composite aircraft passenger door is lightweight and enables minimal and lowcost processing steps using advanced Resin Transfer Molding ("RTM") technology

This extremely cost effective patented door is 30 percent lighter than current same size "black aluminum" designs, avoiding extra processes such as riveting, screwing or robotically stitched performs, and instead, including plain weave fabric and unidirectional tape that exploits the anisotropic characteristics of composite materials.

To realize improved life-cycle costs, Cyclone chose to produce this door with toughened epoxy resins, which provide increased impact resistance.