Hall Special Projects
Hall, Inc. manufactures high-performance custom composite structures. With our aerospace-quality autoclave, we can cure one-piece structures up to 150 ft. in length and 6 ft in diameter in one piece, in one cure cycle. We are also expert at splicing structural tubes; longest to date is 195 feet.
Hall pioneered the construction of seamless, male-molded, autoclave-cured mast tubes. Pre-preg unidirectional carbon fiber is laid up around a mandrel and then autoclave cured at 85-100 psi pressure and a temperature of 250°F. Mandrel molding produces a homogeneous, seamless carbon tube with optimum weight, strength, and stiffness characteristics. Hall leads the industry in autoclave-cured carbon fiber spar production, curing a greater tonnage of carbon per year over our competitors.
In addition, Hall is expert at female tooling, as well as the construction of superior carbon panels and plates. We also work with Kevlar®, Spectra® and aluminum. Hall's on-site engineering, utilizing both dynamic finite element analysis (FEA) and solid modeling, combined with our machine shop, paint shop, and composite shop, will help you reduce the number of suppliers needed to complete your project.
Contact:
Ben Hall, Vice President
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401-253-4858
Long Part Expertise
Our autoclave can cure single-piece structures up to 150 feet long. We're experts at splicing structural tubes and regularly build structures longer than 150 feet.
High-Performance Parts
Hall technicians are experienced with female molding as well as creating superior carbon panels and plates. These are not cookie-cutter parts - our technicians are skilled craftsmen who can create the proper mold for the part.
Complex Structures
Hall is an experienced subcontractor, manufacturing complex structures for a number of uses.
- Missile Reloader: CLAWS and SLAAM RAM Projects. Missile reloader system fit to mobile HMMWVs. Assembly includes autoclave-cured carbon tubes, CNC machined stainless steel and G10 components. CARC Paint Systems being used by both Army and Marines. Subcontract through Raytheon.
- Submarine Structural Component: Currently producing autoclave-cured carbon-fiber tubes as the main structural component (fuselage) for unmanned surveillance submarines. Customers are Oceaneering and Ocean Server.
- Navigation Mast: Currently working on design for a custom tubular structure for holding ship's radar system. Parts will be all autoclave-cured carbon. Details classified. Subcontract through Raytheon.
- Custom Missile Loading Strut: Heavy-duty autoclave-cured carbon strut to assist missile loading onto various Air Force bombers. Details classified.
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