Facility Questions View All

How large is the ICT facility in Tijuana?

The facility is 300,000 square feet.

Why did ICT choose to have a facility in Tijuana?

Tijuana offers an ideal balance of access to skilled labor at an affordable cost. We also believe there is an advantage to being located in North America and just about an hour from San Diego, where we’re closer to our many of our suppliers and business partners than other low cost country manufacturing operations.   

What is your training program for technicians?

ICT has developed our own workforce education program, which begins with basic training in lamination and bonding and continues with functional, on-the-job training as technicians advance through a system of tiered workstations.

The training program is designed to enable technicians to learn and work their way up to more complicated parts as they progress. Video and digital work instructions amplify and help reinforce the on-the-job components. 

Production Questions View All

What manufacturing processes do you utilize?

We offer layup, curing, trim and drill, bonding, and painting operations. The layup process consists of vacuum bagging parts that are laid up by hand using lasers that ensure ply placement accuracy.  We utilize CNC machining to trim and drill component parts after layup and also have automotive style bodywork and painting facilities on site. Our bonding process is exacting and we routinely deal with complex bonded assemblies which require tight tolerances.

What type of composite material do you use?

The ICON A5 is constructed from an epoxy/carbon fiber pre-preg material. Our facility and equipment are capable of handling a wide variety of composite materials and our engineering team has the experience to process all types of materials.

What are the molds for your composite parts made from?

Molds are crafted from nickel-iron alloy as well as aluminum.

How does the layup process work?

The layup process begins with raw material in roll form. We then use automated ply cutting equipment to cut the roll into pre-determined shapes and patterns based on the specific part being produced. The cut pieces are placed by hand with guidance from lasers into a mold or form tool in multiple layers, depending on the strength required for that specific part. The mold is then sealed and vacuum bagged before undergoing a curing process to harden the material.

How are parts cured?

After the layup process is complete, bagged parts are placed in an oven or autoclave. The oven heats to temperatures in excess of 250 degrees F for up to 100 minutes. The autoclave curing process heats the part and also exposes it to pressure. The amount of pressure is dependent on the type of material and the construction of the part. The added pressure in the autoclave produces parts with lower void content and better fiber compaction, which results in a stronger material.

Working with Us View All

How long does it take to get up and running on a contract or project with ICT?

Depending on the level of sophistication and tooling required, ICT can start contract manufacturing carbon fiber parts in anywhere from just a few days for simple parts requiring minimal tooling to a few weeks for the more complex structures. 

How do I get more information on partnering with ICT to produce composite parts for my company?

Contact us by filling out this form or email us at composites@iconaircraft.com and our business development team will respond quickly and set up a meeting.

Partner with us

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