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Composite Bonding Systems for Aerospace and Industrial Applications

GracoRoberts supplies composite bonding systems for applications where joint strength, weight efficiency, and long-term durability are critical. Our portfolio includes structural paste adhesives, epoxy film adhesives, core splice adhesives, and syntactic systems sourced from leading manufacturers and qualified to aerospace and defense program requirements.

Whether you are bonding composite skins to honeycomb core, joining dissimilar materials in a structural assembly, or sealing edges on a composite panel, our bonding systems support the full range of composite joining processes from prototype through production.

Explore our adhesives range for the complete product catalogue, or read on to understand how to select the right bonding system for your application.

Types of Composite Bonding Systems

This overview helps engineers and procurement professionals compare bonding system formats for structural, core, and surface composite applications.

Structural Paste Adhesives

Two-part epoxy and methacrylate paste adhesives for bonding composite assemblies where high peel strength, elevated temperature performance, and gap-filling capability are required. Used in airframe assembly, control surface bonding, and structural repair.

Epoxy Film Adhesives

Supported and unsupported film adhesives for composite-to-composite and composite-to-metal bonding. Film adhesives provide controlled bondline thickness, consistent coverage, and high structural performance in autoclave and out-of-autoclave cure processes. Available in a range of areal weights to suit layup requirements.

Core Splice Adhesives

Foaming and non-foaming core splice systems for joining honeycomb core sections in sandwich panel construction. Designed to fill gaps, bond core-to-core interfaces, and maintain panel integrity through thermal and mechanical cycling.

Syntactic and Void-Filling Compounds

Low-density epoxy syntactic systems and void-filling compounds for edge filling, potting, and core replacement applications. Used where weight is critical and structural continuity must be maintained through complex geometry.

Applications and Measurable Benefits

Airframe and Structural Assembly

Structural film and paste adhesives support primary and secondary bonding in airframes, control surfaces, and nacelles, delivering high peel and shear strength while minimising fastener count and overall weight.

Sandwich Panel Construction

Core splice adhesives and film adhesives are designed for sandwich panel manufacture, bonding skins to core, joining core sections, and sealing panel edges without compromising structural performance.

UAV and Unmanned Systems

Lightweight paste and film adhesive systems support composite bonding in UAV fuselage and wing assemblies where strength-to-weight ratios and cure temperature constraints are key selection factors.

MRO and Structural Repair

Fast-cure paste adhesives and syntactic compounds support in-service repair of composite structures, providing qualified bond performance in field and depot maintenance environments.

Our composite bonding systems help engineers and procurement teams select the right adhesive chemistry, form factor, and cure schedule to meet structural, processing, and qualification requirements.

Manufacturing Methods and Material Readiness

Epoxy film adhesives are compatible with autoclave and press cure processes and can be supplied in slit widths and short rolls to suit layup requirements. Paste adhesives are available in cartridge, semkit, and bulk formats to match dispensing equipment and production volume.

We work with customers on adhesive selection, cure schedule optimization, and surface preparation requirements to ensure bondline performance meets program specifications. Our surface prep and primers page covers pre-bond treatments compatible with these systems.

Certification, Documentation, and Traceability

We support qualification workflows for composite bonding systems, including lot traceability, shelf life management, and certificates on request. Our team can guide data sheet review, process compatibility, and approved sourcing to help meet program and regulatory requirements.

What we provide:

  • Certificates, COA and COC, on request
  • Lot traceability and shelf life management
  • Data sheets, storage and handling guidance
  • Approved sourcing aligned to program specs

Need help selecting or qualifying a bonding system? Talk to our team about composite bonding solutions tailored to your build and documentation requirements.

Composite Bonding Systems FAQs

What types of adhesives do you stock for composite bonding?

We supply structural paste adhesives, epoxy film adhesives, core splice systems, and syntactic compounds from leading manufacturers including Henkel Loctite, 3M, Huntsman, and Solvay. Products are available across a range of cure temperatures and areal weights to suit different process and performance requirements.

How do I choose between a paste adhesive and a film adhesive for composite bonding?

Film adhesives provide a controlled bondline thickness and consistent coverage, making them well suited to large-area bonding in autoclave processes. Paste adhesives offer more flexibility for complex geometry, gap-filling, and out-of-autoclave or field repair applications. Share your process constraints and performance targets and our team will recommend the right format.

Do you supply film adhesives in slit widths or short rolls?

Yes. We offer kitting and converting services so film adhesives and process materials arrive in the exact format your line requires. See our short roll composites service for more information.

Do you provide certifications and lot traceability for bonding systems?

Yes. We offer certificates on request, COA and COC, lot traceability, and shelf life management to support qualification and program compliance.