Reverse engineering of 3D scans is a critical process in composites manufacturing, allowing for precise digital reconstruction of complex parts. By converting scan data into parametric or surface-based CAD models, engineers can analyze, modify, and reproduce composite components with high accuracy.

Composites often feature intricate geometries, varying material properties, and specialized manufacturing constraints. 3D scan-based reverse engineering helps capture these details, providing a foundation for redesign, performance optimization, and manufacturing improvements. The process typically involves:

• Point Cloud Processing: Capturing high-resolution scan data from composite parts.

• Mesh Optimization: Refining raw scan data to eliminate noise and irregularities.

• Surface and Solid Modeling: Converting mesh data into NURBS surfaces or solid CAD models.

• Design Analysis and Modifications: Adjusting geometries to enhance structural performance or manufacturability.

This approach is widely used in aerospace, automotive, marine, and industrial applications, where composite components require precise replication and validation. Reverse engineering of composites supports tasks such as mold design, quality control, structural assessment, and integration with advanced simulation tools.

By leveraging 3D scanning and CAD reconstruction, engineers can improve design accuracy, reduce lead times, and ensure seamless part integration within composite structures. At CustomCarbonSolutions, we have extensive experience in the reverse engineering process. We can also arrange 3D scanning of your composite products. Contact us for more details.

Our CAD design services support the full lifecycle of composite manufacturing, from master model (plug) creation to molding design and analysis. We develop precise, manufacturable designs tailored to composite processes, ensuring efficiency and performance.

We also specialize in 3D-printed parts, designing for a range of applications. With an in-house small 3D printer, we handle prototyping and custom components, while our partnerships with specialized 3D printing shops enable the production of larger, more complex parts.

Whether for tooling, structural components, or custom solutions, our expertise in CAD for composites ensures high-quality, optimized results.

Precise tooling is the foundation of any composite part and is the most important step in composite manufacturing. We create molds using materials suited to different production needs. For autoclave-cured carbon fiber parts, we manufacture high-temperature prepreg molds, ensuring stability under elevated temperatures and pressures.

To produce these molds, we first cut master models (plugs) from materials such as MDF or epoxy tooling blocks, depending on the application.

For larger production runs and smaller components, we use CNC-machined aluminum molds, offering durability and thermal efficiency. Each mold is designed for accuracy, repeatability, and compatibility with composite processes. 

Our composite part production service specializes in carbon fiber components, catering to a wide range of industries such as aerospace, automotive, marine, and industrial applications. We are equipped to handle both small and large series production, offering flexibility in part sizes and quantities.

A crucial part of our process is the use of a large autoclave (3000mm x 2000mm in diameter), which enables us to cure composite materials under controlled temperature and pressure. This helps achieve consistent results, ensuring that parts have minimal porosity and meet structural integrity requirements. The autoclave process plays a significant role in improving the strength and durability of the finished parts.

We primarily work with prepreg carbon fiber, which provides a controlled fiber-to-resin ratio, resulting in parts that are both lightweight and strong. Through careful layup techniques and vacuum bagging, we ensure that each part is thoroughly cured and meets the necessary standards for performance.

By utilizing the autoclave and precise manufacturing techniques, we aim to produce parts that meet the required specifications while optimizing for material efficiency and part consistency.

Our trimming and bonding services focus on ensuring precise finishing and strong connections for composite parts. We use both manual and CNC methods for trimming, depending on the complexity and scale of the project. CNC methods are particularly useful for high-precision work or larger production runs, providing consistent and accurate results.

For bonding, we employ a variety of adhesives to join composite parts or integrate additional components. This includes bonding 3D printed inserts (for example, in automotive panels) or adding reinforcement ribs (such as those in drone fuselages) to enhance structural integrity.

Painting composite parts requires specialized techniques due to the inherent porosity of composite materials, which can make achieving a perfect, pinhole-free finish challenging. Over the years, we have refined our painting process through trial and error, and we now offer top-quality finishes that meet the highest standards, even for the most demanding applications.

We provide a range of painting services, including RAL colored paint jobs, as well as various clear or matte coatings. Whether the goal is to achieve a glossy, high-end finish or a durable, matte surface, we tailor our approach to meet specific customer needs and ensure a consistent, flawless result.

Our experience in painting composite parts extends to some of the most premium aftermarket automotive components, where precision is critical, and any imperfections are not acceptable. This level of expertise allows us to offer a pinhole-free finish with minimal visible defects.

To achieve this, we utilize an in-house 7x4m downdraft paint booth, which provides optimal airflow and dust control, ensuring that the painted surface is clean and smooth. The booth is designed to handle large composite parts, ensuring an even and consistent application of paint across the entire surface.

With years of experience and continuous refinement of our painting techniques, we confidently provide a high-quality, durable finish for composite parts, regardless of their size or complexity.

We provide composite repair services for carbon fiber parts, addressing both cosmetic and mechanical damage. For cosmetic repairs, we focus on issues like scratches, fading, or surface blemishes. These are typically fixed by re-sanding the affected area and re-coating with the desired finish (e.g., glossy, matte). This process restores the part’s appearance while maintaining the structural integrity of the composite material.

For mechanical repairs, we handle more substantial damage, such as cracks or breaks in the composite structure. The repair process involves reinforcing the damaged area, re-laminating it with compatible materials, and ensuring the part retains its strength and functionality. This type of repair is commonly required in industries like automotive, aerospace, and marine, where the part must both look good and perform well under stress.

By understanding the characteristics of carbon fiber and other composite materials, we use appropriate repair techniques to restore both aesthetic quality and structural performance. Each repair is performed with careful consideration to maintain the integrity and intended use of the part.