Composites manufacturing

The manufacturing process

Formtech Composites are well equipped for both Prototype Composites Manufacturing. Suitable for demonstrators / prototypes and proof of concept, but also for Small Volume and Serial Production of composite structures. Small-volume manufacturing is usually the best approach for the motorsports sector, where designs may be updated several times throughout the season.

01

Detailed Drawing

Detailed design specifications for part manufacture provided from FEA / Concepts.

02

Productionisation

Draping analysis create laminate definitions for manufacturing using Anaglyph “Laminate Tools”.

03

Template Creation

In order to automate the kit cutting of material it is necessary to take the draped plies and unfold them to create a nested kit to cut.

04

Kit Cutting

All kit definitions are passed to the 2D kit cutting machine to cut material for subsequent laminating. Kits are then stored for manufacture.

05

Process Control

All aspects of a project are controlled by internal quality management / production system. Works orders are the controlling documentation for all processes and a record of quality.

06

Laminating

Components are laminated in a Clean Room environment; Augmented Reality systems are used to control work processes.

07

Curing

Fully Traceable Autoclave, Oven and heated Press processing is used to apply temperature and pressure to manufacture composite components.

08

Trimming & Assembly

Main trimming takes place in the trim boot with air extraction. Minor trimming work and subsequent assembly takes place in a dedicated area for trimming and assembly.

09

Quality

All aspects of the process of manufacturing are controlled and monitored and fully traceable.