Transform your vision into reality through our process of comprehensive composite manufacturing. From initial consultation to final installation, we guide you through every step with precision, expertise, and unwavering commitment to quality.
Step 1: Free Consultation & Idea Discussion
Your Journey Through Our Process Begins Here
Every great composite project starts with a conversation. Our initial consultation is designed to understand your unique requirements, challenges, and vision.
What We Cover:
- Project scope and objectives discussion
- Material requirements assessment
- Performance specifications review
- Budget and timeline considerations
- Technical feasibility evaluation
- Initial design concepts exploration
What You Can Expect:
- No-obligation consultation with our engineering team
- Expert advice on material selection and design approaches
- Preliminary assessment of manufacturing methods
- Clear project roadmap and next steps
- Transparent pricing discussion
Ready to start? Contact us today to schedule your free consultation and bring your composite project to life.
Step 2: Project Design & Concept Development
Bringing Ideas to Reality
In this phase of our process, our expert team transforms your concepts into precise, manufacturable designs using modern CAD software and engineering principles.
Our Design Process:
- 3D Modelling: Creating detailed digital representations of your component
- Engineering Analysis: Structural integrity and performance optimisation
- Material Specification: Selecting optimal fibre types, resin systems, and layup schedules
- Manufacturing Feasibility: Ensuring designs are optimised for production
- Collaborative Refinement: Working closely with you to perfect every detail
Design Considerations:
- Mechanical performance requirements
- Environmental conditions and durability
- Weight optimisation strategies
- Cost-effective manufacturing approaches
- Integration with existing systems
- Aesthetic and finishing requirements
Deliverables:
- Detailed CAD models and technical drawings
- Material specifications and layup schedules
- Performance analysis reports
- Manufacturing process recommendations
- Project timeline and cost estimates
Step 3: Pattern & Mould Making
Precision Tooling for Perfect Parts
The foundation of exceptional composite parts lies in our process of precision tooling. Our skilled craftsmen create patterns and moulds that ensure dimensional accuracy and surface quality.
Pattern Development:
- Master Pattern Creation:
Building the initial form using various materials and techniques - Dimensional Verification:
Ensuring accuracy to specified tolerances - Surface Preparation:
Achieving the required finish quality - Pattern Optimisation:
Designing for efficient mould production
Mould Manufacturing:
- Material Selection:
Choosing appropriate mould materials - Fabrication Methods:
Utilising hand lay-up, machining, or composite techniques - Quality Control:
Rigorous inspection and dimensional verification - Surface Treatment:
Applying release systems and surface coatings - Testing & Validation:
Trial runs to ensure optimal performance
Types of Moulds We Create:
- Open moulds for hand lay-up and spray-up processes
- Closed moulds for RTM and compression moulding
- Vacuum infusion tooling
- Autoclave-compatible moulds
- Multi-part moulds for complex geometries
Step 4: Production & Manufacturing
Where Expertise Meets Innovation
Our process of state-of-the-art manufacturing facility combines traditional craftsmanship with modern composite technologies to produce parts that exceed expectations.
Manufacturing Processes:
- Hand Lay-up: Precision manual placement of fibreglass mat for complex geometries and small batches
- Vacuum Infusion: Advanced resin transfer for lightweight, high-strength parts
- Chopper-Gun Fibreglass Spraying: Our gun chops a continuous feed of glass strands, and sprays them together with resin directly onto the mould for speed and efficiency.
Quality Manufacturing Standards:
- Controlled environment processing
- Precise temperature and pressure monitoring
- Rigorous material handling protocols
- In-process quality checkpoints
- Traceability throughout production
- Compliance with industry standards
Materials We Work With:
- Carbon fibre (various grades and weaves)
- Fibreglass (E-glass, S-glass)
- Aramid fibres (Kevlar)
- All modern resins, including vinyl ester, and polyester resins
- Specialised core materials
Production Capabilities:
- Small prototype runs to large-scale production
- Parts ranging from grams to several tons
- Complex geometries and multi-part assemblies
- Various finish options and treatments
- Secondary operations (machining, drilling, bonding)
Step 5: Quality Control & Testing
Ensuring Excellence in Every Part
Quality is never compromised at The Composite Group. In this phase of our process, our comprehensive quality control ensures every component meets or exceeds specifications.
Quality Control Measures:
- Incoming Material Inspection: Verifying all raw materials meet specifications
- In-Process Monitoring: Continuous quality checkpoints during manufacturing
- Final Inspection: Comprehensive dimensional and visual inspection
- Mechanical Testing: Strength, stiffness, and durability verification when required
- Documentation: Complete quality records and certification
Testing Capabilities:
- Visual inspection for surface defects
- Laminate thickness measurements
- Void content analysis
- Environmental testing (UV, moisture, temperature cycling)
- Custom testing protocols per customer requirements
Certifications & Standards:
- Proven quality management systems
- Industry-specific certifications
- Material traceability documentation
- Test reports and certificates of conformance
Step 6: Finishing & Surface Treatment
The Perfect Final Touch
Our finishing capabilities ensure your composite parts not only perform exceptionally but also meet aesthetic and functional surface requirements.
Surface Finishing Options:
- Gel Coat Applications: High-gloss, weather-resistant finishes
- Paint Systems: Custom colours and specialty coatings
- Machining: Precision trimming and hole drilling
- Bonding Preparation: Surface treatments for secondary assembly
- Texture Application: Non-slip, decorative, or functional textures
Secondary Operations:
- Quality machining and trimming
- Hole drilling and threading
- Insert installation
- Assembly and sub-assembly
- Packaging for protection during shipping
Step 7: Installation & Support
Completing Our Process, and Your Project Successfully
Our commitment extends beyond manufacturing. We provide comprehensive installation support and ongoing technical assistance to ensure project success.
Installation Services:
- Technical Support: On-site installation guidance and troubleshooting
- Assembly Assistance: Helping integrate components into larger systems
- Training: Educating your team on proper handling and maintenance
- Documentation: Providing installation manuals and maintenance guidelines
Ongoing Support:
- Warranty Coverage: Comprehensive warranty on materials and workmanship
- Maintenance Programs: Scheduled inspection and maintenance services
- Repair Services: Expert repair and refurbishment capabilities
- Technical Consultation: Ongoing engineering support for modifications or improvements
Project Completion:
- Final quality documentation delivery
- Installation verification and sign-off
- Customer training and handover
- Establishment of ongoing support relationship
Why Choose The Composite Group?
Your Trusted Partner in Composite Excellence
Expertise
Decades of experience in advanced composite manufacturing
Quality
Uncompromising commitment to excellence in every project
Innovation
Cutting-edge technologies and continuous improvement
Collaboration
True partnership approach throughout your project
Flexibility
Adaptable processes to meet unique requirements
Reliability
Proven track record of on-time, on-budget delivery
Ready to Start Your Project?
Contact The Composite Group today to schedule your free consultation and discover how our process can bring your composite vision to life.
- Schedule your free consultation
- Discuss your project requirements
- Receive expert guidance and recommendations
- Begin your journey to composite excellence
Let’s transform your ideas into exceptional composite solutions.