Founder / History

Mr. Lundy graduated with a BSME in 1980 and began his career as a composite stress analyst working for Hercules Aerospace in Magna, Utah. His work involved laminate finite element analysis on filament wound solid rocket motor cases for ICBM class cases as well as joint analysis for the Space Shuttle composite solid rocket. Other projects included classified space structures and oil field tubular joints where a patent was awarded for a unique joint design.

In the mid 80's Mr Lundy joined the ALCOA FiberTec division to be a part of their effort to build an all carbon fiber, 8 place aircraft for Beech Aircraft (Star Ship). His responsibility was project engineering for the Nacelle and cowling with supporting work for the filament wound fuselage. Following the StarShip program, Mr. lundy was involved with design analysis and project engineering for many composite projects during his 10 year duration ranging from helicopter structures to satellite structures to submarine and shoulder missile launch tubes.

One specific program worthy of mention was the MIPM launch tube program for Talley Defense. This project consisted of a telescoping, locking set of tubes with the inner and outer tubes filament wound from high strength fibers. Mr. Lundy was responsible for design, tooling and fabrication as well as development and operation of a 10,000 psi hydro testing work cell. Over 330 sets of inner and outer tubes were built for this program with each unit tested at over 9000 psi.

In addition to component engineering, Mr. Lundy was also extensively involved in the filament winding operations of the company and he developed unique software to aide in developing complex patterns.

Parallel to being employed by FiberTec and working of the Beech Aircraft program, Mr. Lundy started a company called Graflite and designed a 2 place, complex, experimental aircraft made entirely of carbon fiber. Mr. Lundy designed the aerodynamics, structures, retractable landing gear and the manufacturing approach for tooling and composite fabrication. During a 2 year period from 1985-1987 with the help of a partner engineer from Hercules, the team built molds and carbon parts for the entire airframe and performed numerous structural tests of critical components. Fibertec allowed full use of their extensive machine shop after hours where Mr Lundy machined and TIG welded all the steel and aluminum components for the landing gear, motor mount and actuator fittings.  After some 7000 man hours of fabrication, the aircraft was first flown in July 11, 1987 and 2 weeks later, it was flown to Oshkosh were it debuted. Mr Lundy flew the airplane extensively until 1991 when it was donated to the Experimental Aircraft museum. The GrafLite is listed in the Jane's World Book of Aviation.

In 1990, Mr Lundy's interest in filament winding and computers lead him to design a new filament winding machine with 4 axis of computerized servo control which used a novel position/time table approach to motion control. The system was very different compared to the machines FIBERTEK was using which used cams, followers and very simple 2 axis motions. This new machine was targeted at winding prepreg tow materials onto complex shaped mandrels which required unique eye motion not found in conventional wet winding machines of the day. After 10 months of fabrication in his garage, along with extensive software development, the machine was operational. In September 1991, Mr. Lundy formed a company called "Composite Solutions" and began manufacturing using the new machine. Since inception, Mr. Lundy has managed all aspects of the company. From $50k in sales the first year to $3.5M is sales in 2007, the company has grown to become a valued supplier to many companies. All during the 17 years of operation capabilities have been added expanding personnel, manufacturing and machining operations. In 2000, the company moved into a new facility which now includes over 23,000 square feet of space.  Mr. Lundy remains the sole owner of the company and continues in a capacity that involves management, marketing and technical direction.

• Stress analyst for Hercules Aerospace
• Design Analysis and Project Engineering for Alcoa Fiber Tec
• Designed, built, and flew one of the first all carbon fiber experimental airplanes - Graflite Airplane donated to OshKosh museum
• Designed and built 4-axis filament winding machine aimed at pre-preg winding using pioneering motion control
• 1991 founded Composite Solutions LLC
• 28 yrs. Composites mfg. experience
• 20 yrs. Business ownership experience