CARBON DESIGN
Ultimate design approach
We develop composite parts from concept to serial production – in our plant, at your site or with proven partners under our supervision. We manufacture using RTM, compression moulding (forged carbon / C-SMC, PCM), autoclave and prepreg, vacuum infusion, pultrusion and filament winding, and we paint and dimensionally inspect finished parts in-house.
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Composite Parts Manufacturing – From Design to Series
We manufacture composite parts in carbon, glass and aramid fibre – from prototypes and small to medium batches through to serial production. Our plant runs RTM, autoclave and prepreg, vacuum infusion, compression moulding and forged carbon (C-SMC), and we finish, paint and dimensionally inspect every part in-house.
Production is backed by our own engineering: part design and FEM analysis, mould design and process parameter development. This means we are responsible for your part from the first model to the last piece in the series – with repeatable quality, controlled cycle time and minimal waste. We also manufacture to customer drawings and on customer-supplied moulds.
Design and FEM analisys
Technology selection
Development of tools and manufacturing proces
Verification and optimization
Manufacturing and quality management
Technologies
We manufacture every part in the technology that best fits its geometry, volume and quality requirements. Our plant runs RTM, autoclave and prepreg, vacuum infusion, compression moulding (PCM, wet compression, SMC) and forged carbon (C-SMC), and we paint and dimensionally inspect finished parts in-house.
Our specialism is forged carbon (C-SMC) – parts with complex geometry, including hollow parts. We developed a serial method for manufacturing hollow forged carbon parts that preserves fibre continuity, with material waste of around 0.5% of the part weight. We also produce forged carbon plates up to 30 mm thick.
We work with carbon, glass, aramid, basalt and natural fibres in epoxy, vinylester and bio-based resin systems.
Selected Projects
From hollow forged carbon parts and a serial manufacturing technology for bicycle frame components to the landing gear of an ultralight helicopter – below are the projects we can describe publicly. Most of our work for industrial customers is covered by non-disclosure agreements. We are happy to discuss details in person, including under an NDA.
About Us
The Carbon Design team spent almost 20 years building its expertise in one of Europe’s leading centres of composite technology – and on renewable energy projects. We turned that knowledge into our own technologies and our own production. Today we take customers from concept and FEM analysis to serial parts and quality control.
We developed a proprietary serial method for manufacturing hollow Forged Carbon (C-SMC) parts. The process preserves fibre continuity without shearing or shortening the fibres, which maintains the part’s strength, and keeps material waste to around 0.5% of the part weight with minimal finishing required.
We developed and implemented a serial manufacturing technology for carbon bicycle frame components that reduces production cost and cycle time compared with conventional prepreg lay-up.
We developed a manufacturing technology for carbon fibre profiles with variable shape and cross-section. By modifying both the process and the material system, we achieve a consistent laminate structure and a repeatable surface finish along the entire length of the profile.