Evans Composites

Every component of an aircraft is required to render it airworthy. Damaged or worn parts often result in challenging repairs. Fast, quality repair capabilities, especially during spare part shortages that increase replacement costs, are necessary to avoid expensive downtimes.

A game-changer in aircraft parts maintenance, Evans Composites has a talent for undertaking the most difficult repair projects.

An ISO 9001 and AS9100D-certified and FAA and EASA Part 145 qualified repair station, it specializes in the overhaul of structural and non-structural airframe components, like sheet metal, metal-bonded and composite structures for commercial, corporate, and military aircraft. Its top-notch capabilities help restore components that are often discarded, reduce dependency on spare parts, and decrease replacement costs.

“We’re an aircraft structures repair station capable of designing and completing repairs for the most challenging airframe components,” states Rick Armstrong, president of Evans Composites.

Prompt attention to customer issues, quick turnarounds, competitive pricing, and a creative approach to making aircraft components functional is what gives Evans Composites the differentiating edge.

Involved with the Air Carriers Purchasing Conference, MRO Americas, and the U.S Air Force, Evans Composites excels in the repair of all airframe components, including wings, slats, flaps, rudders, reverse thrusters, inlets, ailerons, and air stairs. In the event no FAA-approved design repair exists for a certain component, it collaborates with its engineering group and organizations offering DER repair and design to implement relevant strategies. Evans Composites is also certified by FAA to manufacture new airframe parts when the need arises to facilitate a repair.

The Path to Excellence

Evans Composites’ journey began in 2001, when the use of advanced composites like Kevlar and carbon fibers surged to confer enhanced strength and validation of airframe component structures. Its founders combined their expertise in autoclave manufacturing and aircraft parts repair to offer airframe components repair in a fast and cost-optimized manner.

To stay ahead of the trend, Evans Composites invested in designing advanced repairs with a focus on carbon fiber repair and composite structure strength evaluation. It expanded its engineering support team and brought in experts to design innovative composite parts repair processes in collaboration with Airbus and Boeing.

Evans Composites was one of the first to repair Boeing 767 and 787 components and is currently working on a large amount of Boeing 777 parts.

It also offers corporate repair services for commercial aircraft. Its repair portfolio encompasses components of Bombardier aircraft like Challenger 300 and CRJ Series, ERJ-145 and E-175 Embraer aircraft, and G400, G450 and G500 Gulfstream aircraft, in addition to the entire fleet of Boeing and Airbus aircraft.

A tier-2 repair provider, Evans Composites delivers repair and overhaul support to military aircraft in numerous U.S. Air Force programs. It is also a leading supplier of repaired airframe parts for the KC-10 Extender flying tanker.

Facilitating Unmatched Composite Repairs

Evans Composites’ proficiency is best demonstrated by an instance involving an APU Silencer, an advanced composite part used for noise reduction that posed a serious repair challenge for a client. To design the repair, Evans Composites’ engineers examined the part’s strength and sustainability and used material substitution and reverse engineering to determine its composition. Once they received FAA’s approval, they restored its previous noise level reduction capability equivalent to new condition.

The team’s services have proven valuable to many clients over the years, including the world-leading cargo airline, FedEx. Upon discovering a challenging fault in a panel in one of their aircraft, they found it difficult to get it repaired or replaced. They also wanted to avoid the logistical hassle of transporting the large panel to repair facilities.

Evans Composites directed its representative to FedEx to determine the issue and relay the information to its engineering team. The team designed a repair plan and performed it in FedEx’s facility, enabling about 60 percent savings.

Evans Composites conducts most of its repair work at its 60,000 square feet facility, which houses state-of-the-art tools and equipment with extensive metal-forming capabilities for performing high-level repairs. It is equipped with two autoclaves and a large batch oven for mending metal sheets, honeycomb bonds, and composites. The facility is slated to expand by another 30,000 square feet in 2024, and will host additional machining capabilities for FAAapproved part fabrication in support of repairs. Evans Composites focuses on delivering quality in its repair services and component manufacturing through intricate qualitychecking processes. Its quality system doubles as quality management, allowing it to set up KPIs for measuring the efficiency of its processes, and tracking and rectifying system failures. Its quality assurance systems are authorized by airline audit teams.

Helping Conquer the Skies

A core team of industry professionals is the driving force behind Evans Composites’ repair capabilities. The team leverages their decades’ worth of experience to assess customer requirements. It also ensures Evans Composites’ shop floor and engineering teams are well-equipped to perform the repairs and determines areas of performance improvement per the AS9120 and AS9100 specifications. The team constantly monitors the processes and advances its competencies. These endeavors ensure Evans Composites leads in the airframe components repair space.

Evans Composites is establishing the best-in-class customer service in the MRO industry. To achieve this, it stays updated on the high-failure airframe components in the market from airline and OEM standpoints. This helps Evans Composites design plans for these components even before a client faces an issue, giving it a competitive edge.

A commitment to gaining more robust capabilities propels Evans Composites forward. Driven to being the ultimate repair destination for the most challenging aircraft overhaul needs, it ensures clients are back to flying as fast and as safely as possible.