Drastic Improvements for Sayer 44 Boom

Recently, CST Composites received a request to replace a broken alloy boom for a Sayer 44. The client wanted to replace the boom with a composite section, whilst keeping the expensive end-fittings. In addition, as with all our clients, cutting down on costs, reducing weight and quick turnaround time were paramount.

In response to this task, CST Composites altered a mandrel so that whilst the boom section would be oval, the rectangular ends required for the existing fittings would be wound as one section. This drastically improves the integrity of the boom as the entire section is produced as a single piece.

Elliptical to rectangular in a single section

Elliptical to rectangular in a single section

In addition, the production was engineered to allow the entire product to be supplied in kit form with easy-to-attach fittings. This shortens the production time, cutting labour costs and ensuring quick turnaround time.

Fittings are easy to attach and look sleek

Fittings are easy to attach and look sleek

Couple these factors with the obvious weight benefits of replacing the 50kg alloy section with a section that only weighs 30kg yet is 20% stiffer due to the use of our Intermediate Modulus fibre, not to mention the impressive aesthetic appeal, and the overall result is a success on every front.

This is just another example of how CST Composites works with the customer to identify problems and engineer a solution that is stronger, lighter, longer lasting, better looking and less expensive than alternative products.