Inside Our Composites Manufacturing Process

Expert Carbon Fiber Contract Manufacturing Services

We provide professional contract manufacturing for custom carbon fiber components, specializing in both visual A-surface parts and high-strength structural elements. Our facility is equipped for high-performance composite production, ensuring precision for every project. Whether you require vacuum resin infusion or prepreg processing, we deliver industrial-grade solutions from prototyping to small-series production, focusing on flawless aesthetics and uncompromising structural integrity.

Glossy carbon fiber ducts made with out-of-autoclave prepreg

Serving clients worldwide

Carbon Fiber Manufacturing Technologies We Use

Scalable production solutions – from cost-effective to high-performance

We specialize in designing, engineering, and manufacturing composite components. From initial concept to finished product, we provide the full process in-house.

Carbon fiber spoiler made for racing application

Scalable Production with Vacuum-Assisted Resin Infusion (VARI)

The essence of the technology is that carbon fabric is placed into the mold and then enclosed in a vacuum bag, where it is compacted under 99% vacuum pressure. This process ensures the fibers are tightly pressed together, resulting in a lightweight component with minimal porosity.

Advantages of resin infusion

It is more cost-effective than prepreg, as it does not require heat-resistant molds
Cost-effective 3D-printed molds for prototyping and small-series production
Easier access to exotic materials such as Kevlar, Innegra, and Diolen
Co-infusion of sandwich materials in a single step for optimal structural integrity

High-Performance Prepreg Manufacturing for Advanced Components

This is a higher-quality technology where woven carbon material, pre-impregnated with resin, is placed into the mold. Under vacuum, the resin system is activated by heat, and crosslinking occurs at elevated temperatures, producing a high-performance, fully cured component.

Pros and cons of carbon prepreg

It enables the production of highly complex components
Higher heat resistance and 10% lighter components
Higher costs due to frozen storage requirements

Wide range of fiber reinforcement for various applications

Available Composite Materials

Carbon

Carbon fiber is our most frequently used material, offering an exceptional balance of low weight and high stiffness. It is ideal for lightweight, high-performance components and provides excellent stiffness, durability, and design flexibility. Available in 2x2 and 4x4 twill as well as plain weave and spread tow, in a wide range of areal weights.

Kevlar

Kevlar is an extremely strong and lightweight synthetic fiber, offering excellent impact and heat resistance, making it ideal for protective gear and composite structures.

Flax

Lightweight and sustainable natural fiber that offers good strength and stiffness. It also provides excellent vibration damping and is an eco-friendly alternative to synthetic fibers in high-performance materials.

Innegra

Innegra is a lightweight, high-strength fiber offering impact resistance, vibration damping, and improved signal transmission for composites.

Lighter, stiffer, and more cost-effective components

Composite sandwich structures

Composite sandwich structures offer an excellent combination of lightweight construction and high stiffness, making them ideal for aerospace, motorsport, and high-performance applications. They also provide improved impact resistance and vibration damping, contributing to longer-lasting, more reliable components. Overall, sandwich structures enable efficient, high-performance designs that meet demanding engineering requirements at lower cost.

Composite core material for resin infusion

Why we use composites with core materials?

Faster layup times – reducing production time and accelerating project turnaround
Lighter components – lowering overall weight without compromising strength
Enhanced mechanical properties – improving stiffness, durability, and performance

Available sandwich core materials

Nomex or Aluminium Honeycomb
Flexibel non-woven Foams for complex shapes
Rigid PMI & PVC (Rohacell and MyCell) and PET Foam

Additive-manufactured masters and tooling for composite production

Rapid Tooling: 3D Printed Molds & Advanced Toolmaking

We combine additive toolmaking with state-of-the-art carbon fiber processing to drastically reduce lead times and costs. Alongside traditional tool and mold making, we utilize 3D-printed molds and fixtures to enable the fast and precise production of complex prototypes and small-series components. This hybrid approach avoids the high initial costs of conventional tooling while maintaining industrial-grade precision.

3d printed composite mold for carbon fiber production

Completed plug for composite tooling.

Large scale 3d printed mold for composite manufacturing.

Sliced geometry for 3D printing, with connectors for precise alignment.

Carbon fiber intake made with 3d printed mold

Completed carbon part prior to machining.

Want to know more? Let’s talk!

The world of composites is extensive, so we help with a feasibility check to ensure we find the most optimal solution. Learn how we can bring your projects to life with advanced carbon solutions.

talk to a composite expert