When Cirrus Aircraft faced problems of dimensional stability and casting quality with their PUR foam core doors, they turned to Diab for assistance. Diab, in partnership with Creative Foam Composite Systems LLC , came to the rescue with a turnkey doorframe kit.

Reigning over the skies

Cirrus Aircraft, based in Duluth, Minnesota, is the world's largest civilian aircraft manufacturer of private airplanes. So far, it is also the only production airplane manufacturer that uses sandwich composites in the primary structure of its planes. Cirrus has worked with Diab for more than 25 years, and has been more than happy with the reliability and product stability of Diab's composite solutions.

Maximum performance at the lowest weight

Divinycell HT provides the strength, impact resistance, and high temperature process capability that are needed to make lightweight, flight suitable parts for their aircraft. Over 80% of the aircraft is cored with Divinycell including the fuselage and wings. Sandwich construction using Divinycell is critical as it imparts structural strength, and is low in weight.

"Diab, we have a problem"

Historically, Cirrus Aircraft has used a high density PUR foam core for the doors in the SR series aircraft. However, there have been some issues with dimensional stability, and the casting quality has been less than desirable. Cirrus Aircraft reached out to Diab for help with this problem. Diab enlisted Creative Foam Corporation, a world-class provider of innovative solutions in die-cut and molded foam products as well as composite core kits. Together they solved the problem using 5-axis CNC machining for series production to supply a turnkey doorframe kit that replaced high density PUR.

Cleared for take-off now

Cirrus Aircraft has relied on Diab to deliver consistent quality and a steady supply for their manufacturing needs. They were thrilled to find a solution to their doorframe problem that has, in the past, prevented Cirrus from delivering aircraft to their customers. The solution Diab is providing is dimensionally stable, significantly lighter, and a lot more reliable than its predecessor. Cirrus is happy that their customers are queuing up excitedly for delivery.