Charles Alcock is managing editor of the AIN Media Group, having rejoined the company in 2019. He has been an aviation journalist since 1986, and previously worked for AIN from 1990 to 2017, most recently as editor-in-chief. His main focus is on covering new aviation technology and business models, as well as international news.
Having been raised in the London area, Alcock studied at the University of Manchester in the UK and earned an honors degree in Politics and Modern History. He speaks English and French, and some German.

Managing Editor

Charles Alcock

Alpha Metalcraft Group (AMG) believes it can reduce the cost and complexity of specialist manufacturing tasks such as applying the leading-edge guards that prolong the service life of carbon fiber rotary blades. The company is working with OEMs, including developers of new eVTOL aircraft, to introduce an electroplating process in which nickel is directly deposited on composite surfaces rather than making the guards separately and then fitting them to the blades.
The current process involves expensive stainless steel mandrel forms for shaping the nickel abrasion guards. This approach is costly and time-consuming, with five separate steps plus two or more transportation stages to get the finished items installed on the blades.
Mandrels produced to duplicate the shape of the rotorblade can cost up to $100,000 a piece. According to AMG engineering director Luigi Cazzaniga, as many as 80 mandrels might be needed for various parts of an eVTOL aircraft, and in his view, some of the new start-ups in the new advanced air mobility sector have not yet fully considered this or other aspects of preparations for high-volume manufacturing.
“By moving to direct composite plating, we can make the trailing edge as thin as we like, which will also mean weight savings for the aircraft,” Cazzaniga explained. “The ability to directly plate a nickel substrate onto a carbon-filled composite structure eliminates the need for multiple assembly processes and can lower overall manufacturing costs.”
With proof-of-concept engineering work now complete, AMG is partnering with a company called M4 Engineering to make composite panels onto which metal layers that can include lightning strike protection can be electro-deposited. The metal guard can be exposed by abrasion techniques with the nickel and copper layers bonded and embedded into the composites. Essentially, the composite blade acts as its own mandrel.
By the end of the first quarter of this year, the Connecticut-based company expects to be ready to take the next step with a manufacturing partnership. AMG is open to business models that could include licensed manufacturing or establishing facilities close to the aircraft OEMs. With certification issues still to be resolved, Cazzaniga estimated that it could take another 12 to 18 months to achieve full-scale production for the new process.
AMG’s engineering team has conducted strength tests on various direct plating samples to identify specific failure points. This work has led the company to improve the surface abrasion process.

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News and issues relating to business, corporate and private aviation, primarily regarding turbine-engine-powered airplanes and helicopters. Subjects include aircraft, engines, maintenance, operations, personnel, acquisitions, accidents, safety, security, and training.

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