Our manufacturing processes

We specialize in pultrusion, pull-winding, and continuous lamination manufacturing. These processes allow us to produce a broad range of composite profile geometries, from a simple tube to a complex door sill, or a wide side panel for a city bus, and engineer in any number of desired or needed material performance specifications or characteristics.

What is pultrusion?

Pultrusion is a continuous manufacturing process resulting in a steady output of a composite profile which is cut to length at the end of the process. It is called pultrusion because the profile being produced is actually pulled through the process.

The pultrusion process has four main process steps; reinforcement alignment and resin impregnation, shaping and heating in a die; the pulling process, and finally the flying shear cutting.

In the first step, unidirectional (or longitudinal) reinforcing fibers, mats, and fabrics are precisely guided towards the die and impregnated with the prescribed resin. Next the fibers are pulled into a heated die in the shape of the desired profile. The resin is thermally set in this process, creating the desired composite profile.

This profile is then used to pull the reinforcements continuously through the die. Pulling mechanisms grab (friction hold) the newly formed composite profile and pull it in a continuously repeating process.

Finally the finished composite profile is cut to length in line with the continuous movement of the process.

pultrusion_pipe
pultrusion_machinery

What is pull-winding?

The pull-winding process is very similar to the pultrusion process with the exception that in addition to the unidirectional alignment of fibers, the pull-winding process uses helical winding of reinforcements resulting in both the ability to guide unidirectional fibers as well as helical winds (from a few degrees up to 90 degrees). This mix of fiber directions allows for composite advantages such as thinner walls or to meet specific strength or stiffness requirements.

The pull-winding manufacturing process is a continuous process resulting in a steady output of a composite profile which is cut to length at the end of the process. It is called pull-winding because the profile being produced is first “wound” helically with reinforcing fibers (in addition to unidirectional fibers) and then is pulled through the process.

The pull-winding process has four main process steps; reinforcement alignment and resin impregnation, shaping and heating in a die; the pulling process, and finally the flying shear cutting.

In the first step, reinforcing fibers, mats, and fabrics are precisely guided towards the die and impregnated with the prescribed resin. Next the fibers are pulled into a heated die in the shape of the desired profile. The resin is thermally set in this process, creating the desired composite profile.

This profile is then used to pull the reinforcements continuously through the die. Pulling mechanisms grab (friction hold) the newly formed composite profile and pull it in a continuously repeating process.

Finally the finished composite profile is cut to length in line with the continuous movement of the process.

pullwinding_pipe
pullwinding_machinery

What is continuous lamination?

Continuous lamination is used to produce very thin (from 0.3mm up to 1.1mm) and or very wide (approximately 1200mm) laminates. The process begins with aligning and impregnating reinforcements with resin which are then pressed and guided into the desired lay-up. This lay-up may be comprised of several reinforcing layers depending on the strength, stiffness, and other required mechanical properties.

Next the lay-up is cured under pressure and heat to achieve the desired mechanical properties.

Finally the laminate is cut to length.