Manufacturing Processes

Filament Winding - Tubing, Tanks, Pressure Vessels
Continuous strands of fiber are impregnated (or pre-impregnated) with resin, wound onto a mandrel at various computer controlled angles, externally pressurized for compaction, and then heat cured to solidify.  Filament winding is the most automated process available for producing composite tubing and tanks.

Roll-Wrapping - Tubing
Sheets of pre-impregnated fibers ("pre-preg") are wrapped onto a mandrel in multiple layers and angles, externally pressurized, and then heat cured to solidify.  Roll-wrapping is primarily used for producing smaller diameter tubes such as arrow shafts, tent poles, golf shafts, fishing rods, bicycle tubing, hockey sticks, etc.

Compression Molding - Plates, Panels, or any Solid Core Non-Tubular Structure
Impregnated sheets of fiber (either "pre-preg" or "wet" laminate) are compressed between two heated plates inside a mold cavity to simultaneously consolidate and heat cure for solidification.  Compression molding often is utilized for producing flat plates or other nearly flat shaped structures.

Bladder Molding - Any Hollow Structure Other Than a Simple Tube
Impregnated sheets of fiber (either "pre-preg" or "wet" laminate) are wrapped around an inflatable bladder and then placed inside a mold cavity.  Once the mold is closed, pressure is applied to the inside of the bladder pushing the sheets of fiber out against the inside walls of the mold.  Heat is then applied to the mold to solidify (cure) the sheets of fiber in the shape of the inside of the mold.  Once the part is solidified, the bladder is deflated, the mold is then opened for part removal and the bladder is removed (in most cases) from the inside of the final part.

Foam Core Molding - Any Foam Core Structure Other Than a Simple Tube
Foam core molding is very similar to bladder molding except that a heat activated expanding foam core is used in place of an inflatable bladder.  In most cases, the lightweight foam core is left in the final part for structural reinforcement but in some cases it will be removed.

Bonding - Composite Solutions has Extensive Experience Bonding Composites to Composites and Bonding Metal to Composites.
When executed correctly, bonding of composite parts can result in a joint that is as strong or stronger than a welded metal joint.  The bonding process, however, can be a daunting undertaking to someone unfamiliar with adhesives and adhesive chemistry.  Composite Solutions has many years' experience bonding composites and will assist you whether you decide to bond parts yourself or have us bond parts for you.  Since surface prep., technique, adhesive choice, and cure is critical to successful bonding, put our experience to work to help insure your success.