#217 Engineering the DA62: Inside Diamond Aircraft’s Composite Production

Inside Diamond Aircraft: Composite Manufacturing Deep Dive | DA62
| AERO 2026

This 33 minute full length engineering interview takes you inside
the composite manufacturing heart of Diamond Aircraft at Wiener
Neustadt, Austria — one of the most advanced composite aircraft
production sites in General Aviation.

Recorded as part of the AERO Friedrichshafen 2026 preparation,
this episode features a deep technical walkthrough with Gerhard
Hüttinger, Quality Manager at Diamond Aircraft, guided by Norbert
Werle (Founder, JET Circle) and Ilkay Özkisaoglu (DER Social CEO
& Co Founder, Composites Lounge).
The focus of this video is not marketing — it is process,
structure, safety, certification and engineering logic behind
Diamond’s composite aircraft, with special attention to the DA62
as a benchmark for composite driven business and multi mission
aviation.
 
What You Will Learn in This Interview
How Diamond manufactures 95% of its aircraft structure in house
using advanced composite processes
The difference between wet lay up, vacuum assisted infusion, and
“just in time prepreg” workflows
Why Diamond deliberately avoids classical autoclave curing — and
how post curing up to 125°C achieves final strength
How carbon fiber, glass fiber, Kevlar and foam sandwich
structures are combined for optimal stiffness to weight
ratios
Why the DA62 airframe is ~98% carbon fiber
Lightning protection strategies: conductive carbon layers,
aluminum skeletons, copper foils, conductive paint systems
Structural bonding philosophy — including epoxy bonding pastes
capable of filling gaps up to 10 mm
Why Diamond designs for failsafe structures and unlimited
lifetime concepts
How landing gear loads, crash energy (26g), and impact absorption
are managed through composite optimized seat structures
Precision CNC cutting and manual finishing — where automation
ends and craftsmanship begins
Full serial traceability from raw material to delivered
aircraft
Why Diamond prefers aluminum fuel tanks over wet wings in
composite aircraft
Composite center wing box philosophy and fuel safety between twin
spars
Installation logic for radar, avionics, oxygen systems, de icing,
and special mission configurations
 
️ Why This Matters
Composite aircraft manufacturing is no longer an experimental
discipline — it is a mature, safety critical engineering system
shaping the future of General and Business Aviation.
Diamond Aircraft demonstrates how composites: • Reduce weight
without compromising crash safety
• Enable modular manufacturing and scalable production
• Support business travel, charter, training, and special mission
use cases
• Deliver long lifecycle durability with predictable
maintenance
For engineers, OEMs, suppliers, regulators, flight operators, and
composite professionals, this interview offers real production
insight — not slides, not theory.
 
About This Series
This video is part of the Composites Lounge × JET Circle field
research series ahead of AERO Friedrichshafen 2026, documenting
how materials, engineering and business aviation intersect in
real manufacturing environments.
Recorded on site at Diamond Aircraft, Wiener Neustadt
Full factory walk through
Zero scripting, engineering level explanations
 
SEO Keywords & Topics
Diamond Aircraft composies, DA62 manufacturing, composite
aircraft production, carbon fiber aviation, vacuum infusion
composites, General Aviation composites, business aviation
engineering, AERO 2026, Diamond DA62 structure, lightning
protection aircraft, composite fuselage, aviation quality
management, composite bonding aviation, failsafe aircraft
design



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