2021
In Tulkas' early years, design validation, mold preparation, lamination, cure, finishing and testing activities carried out within the same space created a need for a more planned layout as the number of projects and product variety grew. The workshop expansion carried out in 2021 was planned not just to gain more physical space, but to improve quality and repeatability by separating composite production steps from one another.
The new layout aimed to let material preparation, mold operations, lamination, post-cure finishing and measurement activities proceed without crossing each other. This arrangement made it easier to work on multiple prototypes and molds at the same time, while also helping reduce risks such as dust, contamination and material mix-ups that can occur during production.
In carbon fiber propeller manufacturing, every stage from mold preparation to part balancing directly affects product performance. During the workshop expansion, attention was paid to preserving mold surfaces, organized storage of fiber and consumable materials, controlled resin preparation and safely transferring cured parts to finishing.
The reorganization of the production area also made it easier to manage propeller molds of different diameters and pitches. As the mold inventory grew, processes such as numbering, production recipes and sample tracking were aligned with the physical production flow.
In Tulkas' development model, testing the produced part and feeding the results back into redesign holds an important place. The workshop expansion sped up the transition between production and in-house thrust, structural and dimensional controls. The operational steps needed to turn a design revision into a mold, a sample and a test became more visible and manageable.
As a result, prototype production and preparation for series production stopped being entirely separate processes. Production data obtained during the prototype stage began to be used later to establish process standards and quality control points.
The 2021 expansion at YTÜ Teknopark formed the operational groundwork for Tulkas' move to a larger, independent production facility in Sancaktepe in 2023. During this period, the company gained not just new equipment and space, but significant experience in how to segment the production flow, organize material movement, and match test results with production records.
For Tulkas, the workshop expansion was an important step in the transition from R&D-focused prototype manufacturing to a more organized and scalable composite production structure.
You can evaluate Tulkas' composite manufacturing approach, from prototype to repeatable production, for your project.
