World First, Homogeneous Curing with Turbulent Flow,

Composite Autoclave

Autoclaves
Autoclaves

We manufacture high-capacity composite autoclaves with electric or thermal oil heating, up to 5500 mm in diameter and 61 m in length, operating between 1–70 bar. Contact us for custom solutions.

Composite autoclaves are fully compliant with Boeing D6-49327, NADCAP, Airbus, and AMS2750 standards, and are designed and manufactured according to 2014/68/EU (PED), ASME Sec VIII Div.1 (U&S), and EAC (GOST) regulations.

Advantages of Composite Autoclaves

Fatigue calculation allowing up to 25,000 cycles at maximum stress (pressure)
Our control system offers the latest advancements in composite precision process controls and testing systems. It complies with all current and known future requirements of governmental organizations and OEM aviation composite part standards (e.g., Airbus AIPI-03-02-019 and AP-3222-E, Boeing, FAA, EASA).
Seamless operational control with state-of-the-art hardware and software
Turbulent air circulation system ensuring homogeneous heat distribution
Maximum energy saving and control thanks to high-quality thermal insulation
User-friendly heating and cooling battery systems ensuring easy maintenance and operation
Designed and manufactured with the highest safety measures and superior durability
Turnkey Solutions: Cooling, Vacuum, Pressurization (Air and Nitrogen), Loading systems
Recipe control and reporting
Exclusive to our company: water-cooled electric motor for excellent, long-lasting air circulation
Patented lid safety system that activates mechanically under 0.1 Bar and cannot be opened until pressure is fully released
Custom design according to customer requirements
Years of experience in industrial/commercial autoclave technology
Precise pressure and temperature control
Low maintenance and service costs
Easy-to-use interface with TSB Energy control system
The door remains locked until atmospheric pressure and temperature reach a safe level
Alerts are provided to open the drain valve and safety lever before the door can be opened
Autoclave pressurization only begins after confirmation from the door lock mechanisms
High process reliability with remote control capability
Zero emissions at user site, no COx, NOx, or SOx emissions
Customer-specific software revisions provided by our expert team
Autoclave can optionally be equipped with PLC supporting different communication protocols such as Modbus, Profibus, allowing integration into any industrial process

Composites are high-performance engineering materials obtained by combining polymer-based binder resins with high-strength fibers at macro levels. Composite autoclaves aim to bring the material to the best possible physical properties using high heat and pressure. Similar to the heat treatment of steel, composites undergo thermal processes at specific time intervals, pressure, and temperature balances to become ideal materials for the aerospace, space, automotive, defense, and marine industries.

Main materials in production include: aerospace composites, structural components of aircraft and air vehicles, satellites and launchers in the aerospace sector, chassis and accessories in the automotive sector, helicopters and UAVs, carbon fibers, boat and speedboat materials, composite racing systems, high-performance sports equipment, ballistic armor, and special plastics.

Pressurization in these autoclaves is optionally done with air or nitrogen. In nitrogen pressurization, nitrogen can be recovered and reused repeatedly through our partner compressor companies.

Our large-diameter autoclaves are manufactured on-site with our expert engineering team.

Temperature fluctuations can cause issues such as resin-rich or resin-poor areas that may weaken the composite, leading to under-curing or defects. Therefore, temperature is carefully controlled using advanced sensors and automatic control systems. Our aerospace and automotive composite autoclaves are equipped with highly efficient heat transfer systems and precision control software.

Autoclaves used in aerospace, military, and other high-performance industries must be designed with extra care and attention to detail. These autoclaves must meet much higher standards than those used for vulcanization, woodworking, or concrete curing. This is because parts produced in composite autoclaves often end up in the aircraft we fly in or in military equipment protecting our soldiers.

Working Principle of Composite Autoclaves

Our composite autoclaves combine pressurization and cross-linking to properly cure thermoset materials. In aerospace composite production, autoclave curing is traditionally used to remove resin voids and achieve desired fiber content (resin-to-fiber ratio), producing lightweight and strong components.

This process involves placing the part under internal vacuum in the autoclave and externally pressurizing it during the heated curing cycle. The high pressure minimizes resin voids and helps achieve the desired resin/fiber ratio. Temperature and pressure settings vary depending on the material and the desired result.

Design: All our composite autoclaves are designed and manufactured in horizontal or vertical constructions, with single or double doors, with manual or hydraulic-pneumatic arm options, opening from the side or top, in accordance with EN 13445, AD-2000 Merkblatt, Lloyd's Rules, TRD, DIN, EN, PED 2014/68/EC, and ASME Section VIII Div 1. All electrical components are UL labeled and wired according to applicable National Electrical Code requirements.

High-load clamp components are subjected to ultrasonic crack tests and fatigue testing using analysis programs before assembly. Based on customer requests and machine layout, door opening/closing configurations are designed accordingly.

In TSB ENERGY composite autoclaves, air circulation is directed front-to-back using our proprietary baffle design, ensuring airflow contacts all interior areas. Turbulent flow enables fast and evenly distributed heat input across composite materials, achieving temperature uniformity within ±1°C.

During the curing cycle, sensors attached to the composite parts monitor both the part and autoclave air temperatures. Heat loads are balanced through our AI-supported software.

Part quality is directly linked to the quality of vacuum applied to each bagged part. We utilize innovative vacuum systems and control technologies to ensure reliable levels for each cured part.

Our autoclaves not only monitor and control vacuum levels for each part, but also perform automatic leak tests before and during operation. Each leak test generates a report that is stored as part of a permanent data record. Our software includes a 6-step pre-operation integrity check process to verify vacuum systems, parts, and connections, minimizing risks for expensive components.

Our oil cooling unit provides a level of safety unmatched in the industry. Heat from inside the autoclave is transferred to an external oil exchanger via an internal exchanger. Heat load is controlled with 3-way proportional valves with 0.1% precision, offering clients exact cooling curves.

Composite autoclaves are delivered compact and ready-to-operate on a single chassis. Only electrical and cooling water connections are needed.

TSB ENERGY autoclaves are designed to deliver value during operation—not just at purchase.

Ease of Use and Maintenance: User-friendly controls and easy access to components simplify operation and maintenance, reducing downtime and operational costs. One-button start, self-diagnostic safety shutdowns, and control panels featuring maintenance alerts based on usage make autoclave operation safe and intuitive. With advanced remote access, our technical service can quickly assist anywhere in the world.

All safety devices are monitored by PLC. Safety measures are triggered during alarm conditions. Operators control the autoclave via HMI, which displays current and historical alarms. Alarm and operational status are transmitted to other systems via digital dry contacts. Autoclave data and status are retrievable through ModBus, Modbus TCP/IP, and Profinet protocols.

Commissioning is performed by our expert engineers, with full-day, on-equipment training supported by documentation.

Safety: Safety and standards are our top priority. Composite autoclaves are equipped with advanced safety features including: Overpressure and overtemperature protection, Vacuum protection, RF-based door locking sensors, Pilz encrypted safety relay, Mechanical door locking system, Emergency autoclave shutdown mechanisms, Doors remain locked until internal pressure equals atmospheric pressure and temperature reaches a safe level.

Materials: The shell and domes of our composite autoclaves are made of P355GH or P460NL boiler plate steel per EN 10028-2, based on operating temperature and pressure. Nozzle pipes are manufactured from EN 10216-2 compliant P235GH or P265GH seamless boiler tubes. Clamps are produced from forged P355NH (hot rolled rings) or drawn S235JR/S355JR materials.

Efficiency: Our R&D team has developed a fan hood unit that increases airflow volume and pressure inside the autoclave while reducing electric motor power consumption. All autoclaves use proportional valve control to eliminate unnecessary heat input. Front and rear covers and the entire structure are insulated with 50mm thick, 1260°C, 128kg/m3 density ceramic wool to prevent heat loss.

Use of high-efficiency motors results in low electricity consumption.

Eco-Friendly Design: Our emission-free, electric composite autoclaves help reduce your carbon footprint and support carbon neutrality by operating on clean energy.

Customization: We understand every production line and process is unique. With hundreds of proven references, we adapt our equipment to perfectly suit your operation through detailed process analysis. Designing and manufacturing composite autoclaves—and more importantly, supporting successful installation—requires exceptional expertise. With us, you don't just purchase an autoclave; you gain decades of experience and technical excellence. If you have further questions, please don't hesitate to request personalized expert consultation.

Each autoclave can be enhanced with:

AI-supported automation and control developed through university-backed R&D
Extremely high efficiency and low emissions
Standard micro-modulation
Simple and easy maintenance
Rugged design for long service life

What Is a Composite Autoclave

These are pressure vessels heated by thermal oil or electricity, designed to reach specific temperature and pressure levels.

When Is a Composite Autoclave Used?

A composite autoclave is used when manufacturing lightweight, high-strength parts with flawless surface quality. It is essential in aerospace, defense, automotive, and motorsport industries to produce void-free, dimensionally stable composites through precise curing under heat and pressure.