1548 North Gemini Place
Anaheim, CA 92801
714.991.8181
canyoncomposites@earthlink.net
COMPANY INTRODUCTION
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CANYON COMPOSITES COMPETITION SENSITIVE
Canyon Composites, Inc. is a
world class Aerospace
Manufacturer with the
experience and tools necessary
to fabricate and assemble the
most difficult spacecraft and
aerospace structures. Our
customers include:
In our first 10 decade, Canyon Composites Inc
has fabricated more than 201,000 Spacecraft
and Aerospace parts and assemblies.
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Canyon Composites
Profile
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Est. 1996, Privately-owned
Small Business
4-building complex at Anaheim, California
36,000 ft2 of manufacturing facilites.
$4M+ Capital Equipment
45 Employees
Approx. $5M annual sales
10% annual growth - profitable since inception
80% Spacecraft / Satellite
20% Aircraft, Missile and Propulsion
Current Member of SCRA-TCC
Canyon Composites
Campus
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Canyon Composites has over
36,000 ft2 of manufacturing
and assembly space.
Facilities are divided
functionally to provide the
optimal environments for
different processes.
– Composite and Metallic
Machining are separated
for contamination control.
– Each Clean Room has
separate environmental
controls.
Material Storage and Handling
is Aerospace Grade
– Large Computer
Controlled <00F Storage
Capacity.
Canyon Composites
Facilities Overview
•16’ High Bay Ceilings
•High Output Lighting
•Industrial Power
•Compressed Air Supply
•Vacuum Supply
•Filtered Air
•Climate and Humidity Controlled at
700F and 7% rH.
•Maintained and controlled to many
spacecraft manufacturing clean area
requirements.
•Sealed Flooring
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ENVIRONMENTALLY CONTROLLED ASSEMLBY LAB, BUILDING 3
BUILDING ONE
Building One
•Quality Assurance
and Inspection
•Composite
Fabrication
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•Composite
Processing
Canyon Composites
Quality Assurance and Inspection
CMM INSPECTION, QUALITY ASSURANCE DEPARTMENT
Canyon Composites Inc. is
Certified to Quality Standards:
AS9100:2004
Certificate No. 7Y931-AS1
ISO9001:2000
Certificate No.7Y931-1
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ALL PROJECTS MAINTAIN FULL TRACEABILITY, INSPECTION, WORK
INSTRUCTION, AND TESTING DATA.
•Process control by analysis, Mil-spec
inspection and calibration methods.
•Reporting and Data Packages meet or
exceed customer expectations.
Canyon Composites
Materials and Processes Expertise
Typical Materials at Canyon:
Canyon
Typical Processing
Techniques at Canyon:
Canyon
• Epoxy
•Prepreg Lamination
• Cyanate Ester
•Complex Prepreg
Hand Layup
• Bismaleimide
• Polyimide (all NASA, Air Force & Maverick formulations)
•Filament Winding
(4’dia x 20’lg)
• Phenolic
•Tube Wrapping
• Metal and composite Honeycomb
• Adhesives, Core-splice, Titanium, Aluminum, Kapton, etc.
• Ultra-high modulus carbon, Graphite, Astroquartz®, Boron;
•Process Research
and Development
• Ceramic, PBO, SiC, Kevlar, E-Glass, S-2 Glass
•Structural Assembly
Cure Process
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•Soft Tooling
Part Envelope
Thermal Envelope
Available Equipment
Vacuum-Oven
Up to 14’x14’x14’
< 6000F
2 Available Vac-Ovens Onsite
Autoclave – High Temp
Up to 5’ Diameter x 10’ Deep
<8000F
3 Available Autoclaves Onsite
Autoclave – 3500F
10’ Diameter x 20’ Deep
<5000F
Available Autoclaves Offsite
Composites Processing Capability
Canyon Composites
Composite Processing Expertise
PRECISION HAND LAYUP
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HIGH TEMPERATURE AUTOCLAVES
4’ X 20’ FILAMENT WINDING
DIMENSIONALY STABLE STRUCTURE LAMINATION
BUILDING TWO
Building Two
•Composite CNC
Machining
•Composite
Conventional
Machining
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•Panel Routing
Canyon Composites
Composite Machining
Full Service Composite Machining:
•Composite Prototyping, R&D, and Production.
•Separated Metallics and Composite machining facilities for
contamination control.
•Cleanliness, Contamination, and Environmental control in
all machining areas.
•Skilled machinists with experience in conventional and
exotic materials.
•Finishing and Post Processing capability.
•Full Service Conventional and CNC machining capability.
CONVENTIONAL COMPOSITE MACHINING
COMPOSITE MACHINING CAPABILITY
•Spacecraft Level Tolerances: +/- .0001,
.003 True Position
•Piece Part Envelope:15” x 48” x 24”
•Structural Panels Envelope:144” x 144” x 5”
CNC HIGH SPEED COMPOSITE ROUTING
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Canyon Composites
Composite Machining Examples
Canyon has the expertise and equipment to machine complex composites to high
tolerance piecepart configuration. At our facility these tubes, clips, sandwiches, etc. are
laminated, machined, populated with metallics and assembled into structures onsite.
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BUILDING THREE
Building Three
•Environmentally
Controlled
Structural
Assembly
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Canyon Composites
Structural Assembly Lab
Canyon’s Spacecraft Assembly Lab
Includes:
•4000 ft2 of Structures Assembly Area.
•Assembly Environment is computer controlled to 70°F
and 7% Relative Humidity.
•All assembly surfaces within .001” flatness.
•Lab designed to accommodate the largest spacecraft
structures and buses.
Assembly Tables
Starret Pink
Micro Flat
Inspection Tables
6' X 12' X 16"
Assembly Tables
Starret Pink
Micro Flat
Inspection Tables
6' X 12' X 16"
Assembly Tables
Steel
T-Slotted Assembly
Fixtures
22' X 24'
Assembly Tables
Steel
T-Slotted Assembly
Fixtures
22' X 24'
Inspection
QMI / Sonda
Airscan
Panel Air Scanner
60" X 120" X 4"
Assembly Lab Tooling Surfaces
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POST ASSEMBLY FOR MISSLE PAYLOAD ADAPTER
Canyon Composites
Structural Assembly Lab
MISSLE PAYLOAD ADAPTER
LARGE STRUCTURAL ASSEMBLY
SUNSHIELD FRAME ASSEMBLY
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PHOTOGRAMMETRY OF LARGE STABLE STRUCTURE
12’ SPACECRAFT BUS PROTOTYPE
Canyon Composites
Structural Assembly
Common Structural Assembly
Processes Include:
•Paste Adhesive Bonding
•Liquid Shim
•Tack Bonding and Injection
•UV Curing
•RTV Overcoating
•RTV Grounding
•Solder Paste Grounding
•Riveting (all styles)
•Fastening / Striping / Staking
•UV Cure
•Potting
•Tool Supported Insert Bonding
•Tab Method Insert Bonding
HIGH PRECISION STRUCTURAL ASSEMBLY
Canyon is versed in Aerospace grade assembly processes and complies with rigid internal
and customer specifications.
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Building Three
Other Functions
Canyon Composites strives to
enhance employee well being
and provide a comfortable,
streamlined work environment.
A portion of our facilities is
dedicated to our employees.
EMPLOYEE BREAK ROOM
FITNESS ROOM
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FITNESS ROOM
BUILDING FOUR
Building Four
•Conventional
Metallics machining
•CNC Metallics
Machining
•Tooling
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•Structural Testing
Canyon Composites
Metallic Machining
Full Production Machining Capability
•Metallic Prototyping, R&D, and Production.
•Model Based Definition using all major file types.
(.iges, .stp, .acis, .prt, .dwg, .dxf)
•Cleanliness, Contamination, and Environmental
control in all machining areas.
•Skilled machinists with experience in conventional
and exotic materials.
•Finishing and Post Processing capability.
FULL SERVICE CNC MACHINE SHOP
•NAS Fasteners and Inserts for Rapid Turn Around
METALLIC MACHINING CAPABILITY
•Spacecraft Level Tolerances: +/.0001, .001 True Position
•Piece Part Envelope:72” x 36” x 24”
•Materials include Aluminum, Titanium,
Magnesium, Steel, Plastics, Exotic
metals.
FULL SERVICE CONVENTIONAL MACHINING SHOP
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Canyon Composites
Composite Machining Examples
High volume, precision metallic machining facility supports production and sub
assemblies. Canyon can populate your composite structures rapidly, efficiently and with
ultra high precision.
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Canyon Composites
Tooling
Tooling Design and Fabrication
•CTE Compensated Tooling
•Soft or Rigid Tooling
•Weldments, Assemblies, Fixtures
•Composites
•Layup Mandrels
•Assembly Fixtures
•Trim and Drill
TOOLING DESIGN
•Soft Tooling
•Metallics
•Assembly Fixtures
•Trim and Drill Fixtures
•Most standard data files utilized:
.iges, .dwg, .prt, .stp
•Software includes Mastercam,
Inventor, Mechanical Desktop, and
Autocad
TOOLING FABRICATION
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Canyon Composites
Testing
Canyon validates flight hardware
using standard and custom Work In
Process Testing and Mechanical
Verification. We can design tests
to meet your criteria.
TEST NAME
TEST SPEC
Compression Strength and Modulus D695
Density
Customer Requirement
Edge Pullout
CNC Mill
Foam Expansion
CNC Mill
Fiber Volume
D3171
Void Content
D3171
Gel Time
D3532
Hardness, Adhesive
SHORE A,B,C,D
In-Plane Shear
D3518
Insert Pull-out
Customer Requirement
Insert Shear
Customer Requirement
Long Beam Flex
C393
Proof Loading
Customer Requirement
Insert Torque Test
Customer Requirement
Resin Flow
D3531
Short Beam Shear
D2344
T-Peel
D1876
Tensile Strength and Modulus
D3039
Most Common Composite Verification Tests
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ONSITE 20 KIP MECHANICAL TEST LAB
CUSTOM PROOF LOADING
DATA ACQUISITION
Canyon Composites
Machining Capital Equipment List
TYPE
NAME
DESCRIPTION
CNC Horizontal Milling
Center
CNC Horizontal Milling
Center
WORK SIZE XxYxZ
TYPE
NAME
24x32x20
CNC Router
KOMO 1
24x32x20
CNC Router
KOMO 2
CNC Router
KOMO 3
Mill
Bridgeport Mill
Conventional Mill
30x12x16
Mill
Bridgeport Mill
Conventional Mill
30x12x16
Mill
Bridgeport Mill
Conventional Mill
30x12x16
CNC Mill
Haas HS-1
CNC Mill
Haas HS-1
CNC Mill
Haas VF-0E
CNC Veritcal Milling Center
28x14x14
CNC Mill
Haas VF-01
CNC Veritcal Milling Center
32x16x16
CNC Mill
Haas VF-01
CNC Veritcal Milling Center
32x16x16
CNC Mill
Haas VF-3
CNC Veritcal Milling Center
30x16x20
CNC Mill
Haas VF-6
CNC Veritcal Milling Center
32x64x26
CNC Lathe
Haas SL-20
CNC Turning Center
9.0 Dia x 32 Long
CNC Lathe
Mori Seiki SL-150
CNC Turning Center
7.25 Dia x 20.5
Long
Mill
Sajo
Horizontal/Vertical Mill
72x20x20
Mill
Bridgeport Mill
Conventional Mill
30x12x16
Mill
Bridgeport Mill
Conventional Mill
30x12x16
Mill
Acra Vertical Mill
Conventional Mill
36x16x17
Mill
Acra Vertical Mill
CNC Knee Mill
38x15x16
Mill
Supermax
CNC Mill
38x15x16
Lathe
Mori Seiki
Conventional Lathe
37 Long
Lathe
Victor
Conventional Lathe
27 Long
MISC
TOOL ROOM SUPPORT EQUIPMENT (Grinding, Sawing, Blasting,
Welding)
COMPOSITE MACHINING CAPITAL EQUIPMENT
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OTHER
MISC
DESCRIPTION
WORK SIZE XxYxZ
3-Axis High Speed
CNC Router
3-Axis High Speed
CNC Router
3-Axis High Speed
CNC Router
144x144x6
144x60x6
144x60x6
Total Shop Dust
NA
Collection System
TOOL ROOM SUPPORT EQUIPMENT(Grinding, Sawing,
Blasting, Welding)
Torrit
COMPOSITE MACHINING CAPITAL EQUIPMENT
Canyon’s machining capability
in both composites and
metallics is broad and state-ofthe art.
Typical Projects At Canyon
SPACECRAFT
Superbird 6 West
COMPANY
BOEING SATELITE SYSTEMS
MAGNITUDE
CHALLENGES
2 Months
- High precision assembly
- New fabrication techniques
- Strict Shape Requirements
PHOTOGRAMETRY MEASURMENT FOR SURFACE ACCURACY
COMPLETED KEVLAR DUAL GRIDDED REFLECTOR
PHOTOGRAMETRY DOT INSTALLATION
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Typical Projects At Canyon
SPACECRAFT
SPACEWAY
COMPANY
BOEING SATELITE SYSTEMS
MAGNITUDE
CHALLENGES
4 Months, 42 Panels
- Lighweight structural panels
- Hundreds of Embeded Fittings and Fasteners.
- True Position of 0.005 inch, no bonus.
- Coplanarity of 0.002 inch.
SANDWICH PANEL POPULATED WITH METALLIC INSERTS
GROUNDING AND INSPECTION OF ALUMINUM SANDWICH PANEL
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Typical Projects At Canyon
SPACECRAFT
BSAT
COMPANY
ORBITAL SCIENCES
MAGNITUDE
CHALLENGES
4 MONTHS, TUBES, METALICS, PANELS
- Difficult Panels
- Fittings, Brackets, Fasteners CNC'd In House
- Difficult Tubes
COMPLETED STRUCTURAL ASSEMBLY INCLUDING TUBES,
FITTINGS, METALLICS, SANDWICH PANELS, AND LAMINATES
LARGE AND COMPLEX CARBON FIBER TAPERED TUBE
STRUCTURAL COMPOSITE SANDWICH PANELS
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Typical Projects At Canyon
SPACECRAFT
Spaceway
COMPANY
BOEING SATELITE SYSTEMS
MAGNITUDE
CHALLENGES
3 Months, 4 Reflector Shells
- Reflector Shell Fabrication
- Propriery Laminating Configuration
- Strict Shape Requirements
COMPLEX PRECISION LAMINATE PATTERNS
HIGH PRECISION LAMINATES REQUIRE 0 CTE MONOLITHIC GRAPHITE TOOLING.
HIGH PRECISION CARBON FIBER LAMINATE
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Typical Projects At Canyon
SPACECRAFT
COMPANY
MAGNITUDE
CHALLENGES
U.S. ICBM Missle
ATA
5 Months
- Tool Design
- Prototype Fabrication, Machining, and Assembly
- Strict Shape Requirements
MISSLE PAYLOAD ADAPTER ASSEMBLY. TOP CARBON
FIBER SKIN PLACEMENT.
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COMPLEX ASSEMBLY. ALL TOOLING, METALLICS, AND
COMPOSITES WERE FABRICATED AND ASSEMBLED AT CCI.
Typical Projects At Canyon
SPACECRAFT
Superbird 6 East
COMPANY
BOEING SATELITE SYSTEMS
MAGNITUDE
CHALLENGES
2 Months
- High precision assembly
- New fabrication techniques
- Strict Shape Requirements
Proven to .0035 surface RMS
FINISHED STRUCTURE READY FOR INTEGRATION ON SPACECRAFT
ULTRA STABLE CARBON FIBER ANTENNA
INSTALLATION OF PHOTOGRAMETRY DOTS.
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