In the aerospace industry, the demand for lighter, stronger, and more efficient components is always growing. These high-performance needs have led engineers to explore alternatives to traditional materials like metals. One powerful solution is composite manufacturing—a method that creates materials by combining two or more different substances, often resulting in products that are lighter yet stronger than conventional metals.

Historically, aerospace companies used autoclaves—large, pressurised ovens—to cure composite materials. While effective, autoclaves are expensive, energy-hungry, and slow. Today, a better method is gaining popularity: Out-of-Autoclave (OOA) composite manufacturing. This technology is reshaping production methods by saving both time and cost, all while maintaining high structural quality.

Understanding OOA Composite Manufacturing

Out-of-Autoclave (OOA) is a composite manufacturing process where parts are cured using only vacuum pressure and controlled heating, instead of high-pressure autoclaves. The materials used—typically carbon fibre pre-pregs with special resins—are designed to cure properly without the need for intense pressure.

What Makes OOA Different?

• No need for expensive autoclaves

• Lower processing temperatures and pressures

• Energy-efficient curing

• Suitable for large or uniquely shaped parts

• Ideal for short-run or built to print projects

OOA supports build to print manufacturing, which means parts can be made directly from a customer’s design or drawing, allowing for customisation and quicker production cycles.

Saving Time in Aerospace Production

Time is crucial in aerospace projects, especially with tight deadlines, high customer expectations, and intense global competition. OOA composite manufacturing brings significant time-saving benefits, including:

1. Reduced Production Cycle Time

• Traditional autoclave curing may take several hours or even a full day. OOA reduces that time by using lower temperatures and a single heat cycle.

• No pressure ramp-up or cooldown steps means the process flows more smoothly from start to finish.

2. Faster Setup and Turnaround

• Moulds used in OOA are typically lighter and easier to handle.

• Since the process is less equipment-heavy, teams can start production faster and scale more easily.

3. Simpler Tooling and Fixtures

• Unlike autoclave-based systems, OOA doesn’t require pressure-resistant tooling. This flexibility supports built to print projects where unique part shapes are required quickly.

Together, these advantages help aerospace firms meet deadlines, deliver faster to clients, and reduce the time-to-market for new aircraft components.

Cutting Costs with OOA Manufacturing

Traditional composite manufacturing can be expensive due to autoclave investment, energy consumption, and maintenance. OOA significantly lowers these costs:

1. Capital Cost Reduction

• Autoclaves are costly to purchase, install, and maintain.

• OOA eliminates this need, making it ideal for small to mid-sized aerospace suppliers or startups.

2. Lower Energy Usage

• OOA operates at lower temperatures and without pressure systems, drastically cutting energy bills.

• Consumes up to 60% less energy compared to autoclave curing processes.

3. Decreased Labour and Maintenance Costs

• With fewer machines and shorter processing times, manufacturers spend less on labour and maintenance.

• Staff can focus on quality control and innovation rather than operating complex equipment.

4. Reduced Material Waste

• Using precise pre-pregs and vacuum systems means fewer materials are wasted during lay-up and curing.

• Ideal for build to print manufacturing, where accuracy and cost-efficiency are crucial.

By reducing both fixed and variable expenses, OOA helps aerospace companies stay profitable and competitive—especially in a market that’s constantly looking for better, faster, and cheaper solutions.

Why the Aerospace Industry Is Adopting OOA

The shift toward Out-of-Autoclave methods is more than just a trend—it’s a strategic move. As aircraft manufacturers seek sustainable growth, they need processes that offer:

• High-quality results without high infrastructure costs

• Scalability for new product lines or upgraded models

• Flexibility for custom components and built to print parts

• Eco-friendly production with lower energy consumption

OOA technology ticks all these boxes. That’s why many aerospace OEMs (Original Equipment Manufacturers) and suppliers are moving away from autoclaves and embracing OOA as the future of composite manufacturing.

Real-World Applications of OOA in Aerospace

Here’s how OOA is already making a difference:

• Satellite structures: Lightweight panels cured without autoclaves reduce launch costs.

• Unmanned aerial vehicles (UAVs): Custom shapes are easily produced through build to print manufacturing.

• Interior aircraft components: Non-structural parts like seat frames and panels are being efficiently made with OOA.

These examples show that the technology isn’t just theoretical—it's already delivering real savings and benefits in the field.

Conclusion

Out-of-Autoclave (OOA) composite manufacturing is proving to be a smart alternative to traditional autoclave systems. By simplifying the curing process and slashing equipment costs, it helps aerospace companies build high-performance parts faster and more affordably. Combined with the efficiency of build to print manufacturing, OOA allows firms to respond quickly to customer needs, adapt to new technologies, and stay ahead in a demanding market.

As composite materials become more important in aviation, defence, and space, OOA is leading the way—helping the industry save time, reduce waste, and fly further.