An aircraft and its various structures are regularly subject to intense stressors during standard flight operations, thus care and maintenance is crucial for maintaining the health of all parts. During the manufacturing or repair stage, fabric coverings are used for all open structures and closed plywood structures. The aircraft fabric covering process has been a common procedure since the early days of aviation, and there are various materials and methods that may be used.
Fabric coverings serve various important roles, ensuring that aircraft operate optimally during flight. For lifting and control surfaces, the fabric covering may simply serve as a light, airproof skin. For non-lifting parts, fabrics can reduce drag, sometimes even acting as a fairing to the benefit of the aircraft. Beyond such uses, fabric coverings may also strengthen weak structures and/or protect them from exposure to the elements.
When conducting the fabric covering process, one may either use the blanket or envelope method. In regard to the blanket method, fabric is cut and trimmed into various flat sections before being attached to the airframe. Typically, certified greige polyester fabric is a popular choice, and such materials may be used straight from the bolt. Blankets of fabric should be applied after making a determination on what size and layout is best for a given aircraft, and many often use a single cut blanket per small surface for ease.
Due to their size and shape, wings often benefit from the implementation of two blankets that overlap on one another. If the wing is much larger, then a second blanket may be needed so that the entirety of the top and bottom is covered. Fuselages, on the other hand, can utilize numerous blankets that stretch across major structural members, and a single blanket can be sufficient for the belly. For all fabric installations, approved adhesives are relied on.
The envelope method is the alternative to the blanket method, saving time through the use of precut and pre-sewn fabric that can be used to quickly cover the aircraft. As the prefabricated envelopes are produced, they will always be made with an approved thread, fabric fold, edge distance, and other specifications as required by the particular aircraft. While the blanket method requires one to determine the sizing and attachment of each blanket, envelope pieces will allow for the fuselages, wings, and other major structures of aircraft to quickly be closed with a single envelope each.
As the envelopes are specifically sized for each structure, they should be able to slide into place. With adhesives, they can then be secured to the airframe. The seams of each envelope will often be situated in an inconspicuous area of the airframe, generally being near the trailing edge of structures, above or below the fuselage, and other such places. In some instances, the manufacturer or STC will provide guidance on where sewn seams should be located.
If one is planning to replace the fabric of an aircraft using either method, they must first ensure that the old fabric coverings are removed. With razor blades or a utility knife, the aging fabric can be cut off. Due to the use of sharp tools, one should take care in their cutting as to not damage the airframe itself. As old covering is removed, it can be beneficial to take off large sections and notate where all features such as cable guides and inspection panels are located so that they may be used as templates for the installation of new fabric. It is also important to remove all fasteners that are holding down fabric so that it may be safely removed.
With proper fabric removal and installation, an aircraft and its various structures can be well maintained and protected. If you find yourself in need of cable guide components, plywood rolls, sawhorse products, or other various items for your fabric operations, let the experts at NSN Parts Now help you secure everything you need with ease. With over 2 billion new, used, obsolete, and hard-to-find items readily available for purchase at any time, we are your sourcing solution. Due to our dedication to quality control and export compliance, we proudly operate with AS9120B, ISO 9001:2015, and FAA AC 00-56B certification and accreditation. Send us a completed RFQ form at your earliest convenience, and our team of industry experts will reach out to you in just 15 minutes or less, 24/7x365.
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