Ultimate design approach
We design and manufacture composite parts
Composite parts in carbon fibre and other composite materials – from design and moulds to series production with quality control. We specialise in forged carbon (C-SMC) and in parts made from prepregs. Based in Kraków, Poland; we work with customers across Europe.
- Developed in-house – a series method for making hollow forged carbon parts
- approx. 0.5% material waste in this method
- 1–30 mm – plates in forged carbon and other materials
Projects
Three examples of our work
Most industrial projects are under NDA. We show the ones we can talk about – with the task, our role and the result.
Hollow forged carbon parts without cutting the fibres
A series method for making hollow, high-strength forged carbon parts in which the fibres are not cut or shortened. Waste approx. 0.5% of the part mass, patent pending.
Hussar – a quad tailsitter VTOL drone
A joint project with BKODE: a multi-role VTOL unmanned platform in a quad tailsitter layout. Carbon Design is responsible for the geometry design and the composite…
- Period
- 2026 – in progress
- Partners
- BKODE sp. z o.o.
Series production process for carbon fibre bicycle frames
A series production process for carbon fibre bicycle frames that is cheaper and faster than the conventional one.
Photos from our projects – hover to pause, click to enlarge.
Composite plates 1–30 mm: forged carbon, carbon, aramid, glass
Series production process for carbon fibre bicycle frames
Bicycle design: geometry and suspension kinematics
Composite plates 1–30 mm: forged carbon, carbon, aramid, glass
Series production process for carbon fibre bicycle frames
Composite plates 1–30 mm: forged carbon, carbon, aramid, glass
Series production process for carbon fibre bicycle frames
Composite plates 1–30 mm: forged carbon, carbon, aramid, glass
Series production process for carbon fibre bicycle frames
Hollow forged carbon parts without cutting the fibres
Hussar – a quad tailsitter VTOL drone
Hussar – a quad tailsitter VTOL drone
Hollow forged carbon parts without cutting the fibres
Hussar – a quad tailsitter VTOL drone
Propeller blade generator for drones in Siemens Designcenter NX
Hollow forged carbon parts without cutting the fibres
Hussar – a quad tailsitter VTOL drone
Hollow forged carbon parts without cutting the fibres
Hussar – a quad tailsitter VTOL drone
Hollow forged carbon parts without cutting the fibres
Hussar – a quad tailsitter VTOL drone
Series production process for carbon fibre bicycle frames
Series production process for carbon fibre bicycle frames
Series production process for carbon fibre bicycle frames
We work with
Technologies
What we make with each technology
We choose the process for the part and the quantity – not the other way round. We run seven processes in-house and three with partners under our supervision.
Forged carbon (C-SMC, C-BMC)
3D nodes, brackets and connectors with ribs and inserts, hollow parts, 1–30 mm plates.
RAT and prepreg – Reverse Autoclave Technology
Prepreg profiles, frames and tubes pressed by a bladder; panels and covers under a lid.
Compression moulding: PCM, WCM, SQRTM
Thin-walled panels, lids and covers with two finished surfaces.
Prepreg with an expanding core
Closed profiles and frames, arms and beams with foam supporting the walls.
RTM and light RTM (LRTM)
Housings, covers and structural parts with repeatable thickness – from approx. 100 pcs/year.
OOA – out of autoclave
VBO prepreg structures without a chamber size limit, pressed parts, prototypes.
In our plant
- 2 hydraulic presses: 160 t and 40 t
- 3 RAT vacuum ovens and an OOA oven
- 5-axis CNC milling machine for carbon fibre
- plotter for cutting dry fabrics and prepregs, with a marking module
- resin 3D printing up to 250 °C: GK3 Pro, Cure Ultra, Phrozen Wash Mega S
- our own paint shop
- quality control: 3D scanner, microscope, laboratory scale
- vacuum leak testing: thermal imaging and ultrasonic cameras
Composite plates
Forged carbon, and also carbon, aramid and glass plates and any combination of them. Standard thickness 1–30 mm (over 100 mm is technically possible), size 500×500 mm.
Services
How we work with you
You can order the whole project or a single stage. We are happy to sign an NDA before you send any documents.
Design and FEM analysis
Geometry and laminate in Siemens Designcenter NX, FEM calculations – strength, vibration, flow – before any mould is made.
Choice of process
We match the process to the annual volume, the cost of moulds and machining, the available machines and the quality requirements.
Moulds and process
We design moulds in NX Mold Wizard and check them with Moldex3D simulation. We supervise mould making at proven toolmakers.
Verification and optimisation
A trial batch confirms the mould and the process. We tune temperatures, pressure, charge and cycle time.
Production and quality
Series production with an inspection report for every batch: 3D scan, microscopy, vacuum leak testing, process records.
At our plant
Production in our facility – from prototype to series, with every batch inspected.
At your plant
Process transfer to your facility: technology, moulds, parameters and operator training.
With partners
When a part needs a process we do not run ourselves, we supervise it and take responsibility for the result.
Contact
Describe your part – we will propose a process
A description and a sketch are enough. You can attach a drawing, a 3D model (ideally Siemens NX or Parasolid) or a photo to the form – or send it after we sign an NDA.
What to prepare for a quote
- 3D model – ideally a native Siemens NX / Designcenter file (.prt), also Parasolid (.x_t, .x_b), STEP or IGES – or a 2D drawing with tolerances
- Loads and operating environment: temperature, chemicals, UV, moisture
- Planned quantity: prototype, annual volume, whole project lifetime
- Surface requirements: visible carbon, painted, class A
- Deadline and any industry standards or certificates that apply
Direct contact
Carbon Design Sp. z o.o.ul. Walerego Eliasza Radzikowskiego 17/1
31-315 Kraków
+48 604 583 775
+48 538 386 699
office@carbon-design.eu