Projects
Selected projects in composites: forged carbon, bicycle frames, drones, helicopter skids and process lines. Most industrial work is under NDA – we show what we can talk about, with our role and the result.
Ongoing projects
Structures and tools we are developing now – together with partners.
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.
Bicycle design: geometry and suspension kinematics
A bicycle designed from geometry to suspension kinematics – calculated with our own software implemented in Siemens Designcenter NX, on a parametric model.
- Period
- in progress
Propeller blade generator for drones in Siemens Designcenter NX
A blade generator for unmanned aircraft integrated with Siemens Designcenter NX: blades in various configurations, followed by moulds and manufacturing.
- Period
- in progress
EU-funded projects
Projects co-financed by the European Union.
FENG: a manufacturing process for hollow composite parts for the bicycle industry
A project in the FENG programme, measure 1.1 SMART Path: an innovative process for making complex hollow composite parts for the bicycle industry. EU funding: PLN…
- Period
- from 2025
- Funding
- FENG, measure 1.1 SMART Path – EU funding PLN 1,627,314.00
UL-CompPro: ultralight helicopter skids
An AMULET (1st call) project with East 4D Carbon Technology GmbH: skids made of filament-wound profiles and forged carbon connectors.
- Partners
- East 4D Carbon Technology GmbH
- Funding
- AMULET (1st call)
Completed
Details of the projects under NDA we discuss after signing a confidentiality agreement.
Start-up of a pultrusion line for composite concrete rebar
Start-up and optimisation of a production line for composite rebar.
Composite plates 1–30 mm: forged carbon, carbon, aramid, glass
500×500 mm composite plates 1–30 mm thick – forged carbon, carbon, aramid, glass and their combinations – for CNC machining and premium finishes.
Carbon profiles with a variable shape and section
A method for making carbon fibre profiles with a variable outer shape and a variable section.
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.
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.
Have a drawing or just an idea? We will tell you how to make it.
Tell us what the part has to do, how many you need and what the requirements are. We will reply with a proposed process, material and next steps – with no obligation, under NDA if needed.