2023
Tulkas Mühendislik carried the R&D and production capabilities it developed at YTÜ Teknopark to its 300 m² enclosed production facility in Sancaktepe in 2023. This move resulted from the company's goal of building a production structure able to manage higher-volume, repeatable, and multiple product families at the same time, in addition to its project-based prototype production.
The new facility was not treated simply as a larger workshop for relocating existing equipment. The path material follows from entering the facility to the inspection and packaging of the finished product was replanned from scratch. This made it possible to separate clean composite processes, machining and dusty finishing operations, and test activities from one another.
Separate work zones were established at the facility for mold preparation, fiber and consumable storage, lamination, cure, deflashing and surface finishing, measurement, balancing and testing. This segmentation was used to reduce the risk of cross-contamination during production, improve occupational safety, and separate materials and documentation for projects running in parallel.
Organized storage of molds of different diameters and pitches for propeller production, matching production recipes with the correct mold, and tracking parts by series/sample basis were among the key needs of the new layout. The larger space contributed to the effective management of a mold inventory that reached more than 30 diameter-and-pitch combinations.
Tulkas' Sancaktepe facility was organized with the goal of allowing R&D samples and series production parts to proceed without hindering each other. A new profile or ply layup could be produced as a prototype, while planning was made so that repeated production of validated products could continue through standard process steps.
This approach allowed the company to increase process discipline without losing product development flexibility. Recording steps such as mold maintenance, material preparation, cure time, finishing and balancing was used to reduce variability between products and identify the source of potential deviations more quickly.
With the move to Sancaktepe, Tulkas gained more flexible working space not only for carbon fiber propellers but also for rotor blades, carbon tubes, plates and special composite components. Moving large molds and long parts, preparing multiple samples in parallel, and running in-house test systems independently of production all became easier.
The 300 m² enclosed facility was a corporate growth step that advanced Tulkas' production capacity not just in terms of floor area, but also in process control, project separation and readiness for series production.
For your custom composite part, propeller or mold development needs, you can evaluate Tulkas' Sancaktepe production infrastructure and engineering process.
