WAG Wernli to manufacture composite brackets for Aero2

 Dufour Aerospace (Switzerland) announced the selection of WAG Wernli AG to manufacture composites brackets. WAG Wernli is a Swiss-based designer and manufacturer of fiber-reinforced plastic molded parts.The WAG Wernli designs include sheet moulding compound (SMC) material through high pressure and temperature curing processes. It will replace the original aluminium brackets used on the Aero2, enabling the Aero2 to enjoy cost and weight savings. Dufour Aerospace develops efficient and ecological aircraft for patient and passenger transport, logistics and public safety. The first product Dufour Aerospace will launch is the Aero2, an uncrewed aerial vehicle specifically designed for the transportation of critical cargo such as medical supplies of up to 40 kilograms/88 pounds in medium to long range distances.

Simon Bendrey, Head of Design of Dufour Aerospace said: “WAG Wernli is a small, family-run firm that takes pride and care in their work producing quality components in small batch runs. They have a proven track record in hot pressing finished parts directly from moulds using SMC materials, and Dufour is excited to work with them on the manufacture of production support brackets for the Aero2. WAG Wernli will provide lightweight, stiff carbon brackets with exceptional fatigue performance, supporting the main fittings on the aircraft. They offer exceptional value for money when compared to traditional milled aluminium or hand-laminated components. Dufour is looking forward to a successful partnership on the Aero2 programme.”

The combination of different materials, such as aluminium and fiber-reinforced plastics, poses various challenges in terms of assembling quality in aviation. The technology used by WAG Wernli and their SMC-pressing process produces an economical and reproducible carbon molded part for the Aero2. In addition to an economic advantage, the C-SMC products are up to 45% lighter than aluminum components, and they are corrosion-resistant and have good adhesive properties. Inserts such as bearings can be integrated positively into the molded part without the need for subsequent bonding.