Thank you for considering us for your project! When you're ready to introduce yourself, your company, and your project, please use the request a quote form on this page or elsewhere on our site. We typically respond within a business day or two.
Our Free Introductory Consultation
We initially begin with a consultation to see if we can provide a solution for your projects needs and challenges. We then return with quote and a proposed solution regarding materials, process, and tools we need to complete your project. After this step we will work through the steps below to create a mold/tool and deliver a test part for inspection. If no changes are requested, we fabricate the rest of the batch.
Engineering & Development
We understand the challenges associated with engineering and manufacturing composite parts. The most challenging part is determining what to put inside of a part: carbon fiber, fiberglass, Kevlar, epoxy, vinyl ester, Nomex honeycomb or PVC foam; to give a few examples.
Through the engineering phase of a project our goal is to simplify your usage and assembly process by using structural molding and insert molding techniques. We understand that each part and project is unique and can develop a testing schedule to suit the challenges they all possess; whether that is lifecycle testing, fatigue analysis, destructive testing, or deformation measurement.
Tooling
Tools and molds are often the most expensive part of a project. We assess your short and long term goals before building these pieces. Our tools can be prototype grade from machined foam, 3D Printed, or MDF; to large gelcoat-fiberglass mold for resin infusion; to an aluminum mold for fast and efficient pre-preg molding.
Layup & Molding
We specialize in three processes: wet layup, resin-infusion, and out-of-autoclave prepreg manufacturing. Each process has its own unique advantages and price points. So no matter what your production targets, design requirements, and budget is for a project, we are able to provide the correct solution.
Part Curing
It can be as simple as a room temperature cure, to a highly controlled post cure for the optimal material properties. We monitor viscosity and temperature of our resins closely for each part to ensure your parts are perfect every time.
Trimming, Bonding, and Assembly
After a part leaves the mold we begin post-processing by trimming each to size. Secondary processes such as drilling holes and bonding external assemblies/parts are then completed. These bonded pieces can be other composite parts, metal components that contain threaded holes, and even sensitive electronic components.
To ensure quality this process uses custom jigs & fixtures to hold even the strictest of dimensional requirements. These bonded composite assemblies are often lighter and stronger than any bolted or welded metal structures.
Coatings, Gelcoat & Paint
Most parts require a coating, either during or after the molding process to be cosmetic or protective. This can be an in mold gelcoat, a matte or high gloss paint, or a UV resistant clear coat to protect and showcase the final product.
Testing
We consider testing to be the most important step of building anything out of composites. We use this step to confirm a part is performing exactly as it is needed to, deforming and breaking as it was designed to, lasting for its expected lifetime, and even for potentially reducing the weight and cost of a part. We use testing for both the product development/prototyping phase of a project and even during the batch production phase as a QC measure.