R&D · In development
Structures that are grown,
not assembled.
Alongside production work we are developing a proprietary dissolvable-mandrel method for monolithic composite structures. This is research — not a product line we sell today.
The idea
One continuous structure, no bonded joints.
Composite airframes are normally bonded or bolted from separate shells, spars and fittings. Every joint adds mass, fasteners, inspection burden and a stress concentration.
We replace the conventional tool with a sacrificial internal mandrel that dissolves after cure. Because the tool leaves through the part, the laminate can be laid up as one closed structure — internal ribs, webs and passages included.
The target is a monolithic structure: fibres running uninterrupted through what would otherwise be a joint.
Dashed inner profile: sacrificial mandrel geometry. Lower marks: dissolution and evacuation path after cure. Illustrative schematic only.
Status
Where this actually stands.
Stage
Active internal development — formulation, dissolution behaviour and layup sequencing on test geometries.
Not yet proven
Not qualified for flight structures. No performance figures published until we can stand behind them.
Ownership
Method and formulations proprietary to Black Grain, developed in-house.
Forward look
Potential drone and UAV applications.
Research directions, not available capabilities.
Jointless multirotor frames
Arms and centre structure as one piece, removing the junction that governs stiffness.
Closed-section wings
Skins, spar and ribs formed together, with geometry no extractable tool allows.
Integrated fuselage pods
Frames, mounts and routing formed in place instead of bonded in after moulding.
Embedded service routing
Internal channels for wiring or cooling left behind as clean passages.
Collaboration
If bonded joints are the limiting factor on your structure, we're open to development work — with clear expectations on what is production-ready today and what is research.
Talk to us