MANUFACTURING CAPABILITY

Carbon Fiber Manufacturing: From Tooling to Series

We turn your project requirements into a defined manufacturing process—from tooling and prepreg lay-up to finished components.

Technician grinds a hole into a carbon fiber component

END-TO-END MANUFACTURING

A Controlled Route From Design Data to Finished Parts

Reliable composite production starts with decisions made before lay-up. Geometry, tooling, trim strategy, inserts, bonding and surface finish must be planned as one manufacturing system.

We support the complete route—or selected stages—according to the maturity, volume and technical requirements of your project.

Best suited for engineered custom components, prototypes, low-volume batches and repeat B2B production.

01Design Review + Engineering

02Tooling + Mold Manufacturing

03Prepreg Preparation + Lay-up

04Bagging + Autoclave Curing

05Trimming + Assembly

06Quality + Series Production

01ENGINEERING INPUT

Design Review & Composite Engineering

We review the available geometry, functional requirements and intended production volumes before tooling begins. Projects can start with production CAD, scan data, an existing component or an early-stage concept.

  • Geometry and manufacturability review
  • Laminate, interface and surface requirements
  • Agreed manufacturing, tooling and trim strategy
Epoxy master model prepared for manufacturing project-specific composite tooling

Finished carbon fiber component positioned above its machined aluminum tooling

02PRODUCTION FOUNDATIONS

Tooling & Mold Manufacturing

Tooling is developed around part geometry, required surface finish, cure conditions and expected production volumes. Composite or aluminium tooling is selected to balance accuracy, durability and project economics.

  • Composite and aluminium tooling
  • Controlled datums, split lines and trim strategy
  • Tooling route matched to prototype or repeat production

03CONTROLLED LAMINATION

Prepreg Preparation & Lay-up

Prepreg materials are prepared and laid up using controlled templates and defined laminate schedules. Ply orientation, overlaps, local reinforcements and inserts are planned around the structural and cosmetic requirements of the component.

  • Controlled material preparation
  • Accurate ply orientation and reinforcement placement
  • Defined templates and laminate instructions
Technician marks prepreg cutting templates for carbon fiber laminate plies
Technician handles a carbon fiber prepreg ply during manual lay-up preparation

Technician positions vacuum-bagging film around a composite tool before autoclave curing
Technician installs a vacuum connection in the bagging film before autoclave curing

04PREPREG & AUTOCLAVE TECHNOLOGY

Vacuum Bagging & Autoclave Curing

Components are vacuum bagged and cured in the autoclave using defined pressure and temperature parameters. The process supports consistent consolidation, complex geometries and high-quality visible surfaces.

  • Controlled pressure and temperature
  • Defined cure parameters for repeat production
  • Suitable for complex geometries and cosmetic surfaces

Autoclave capacityØ2,000 × 3,000 mm

05DOWNSTREAM OPERATIONS

Trimming, Bonding & Assembly

After curing, components are trimmed, drilled and prepared for final assembly. Inserts, brackets and multi-part assemblies can be integrated using bonded or mechanical joining methods according to project requirements.

  • CNC trimming where appropriate
  • Insert and bracket integration
  • Defined trimming and assembly sequence
Technician grinds a hole into a carbon fiber component

Finished carbon fiber components from a repeat production batch arranged in the CCS workshop
Close-up of a finished carbon fiber component showing weave alignment, edge finish and label

06REPEATABLE OUTPUT

Quality Control & Series Production

Finished components are inspected against project-specific visual, dimensional and fit requirements. Defined production parameters support the transition from initial prototypes to recurring batches.

  • Visual and dimensional inspection
  • Project-specific acceptance criteria
  • Controlled transition from prototype to repeat production

PROJECT INPUTS

What to Send for an Initial Review

01

Geometry

CAD files, drawings, scan data or an existing component.

02

Requirements

Application, loads, interfaces, dimensions and required surface finish.

03

Production Scope

Expected quantity, target timing, budget range and current project stage.

Early-stage concepts are welcome. Complete production data is not required for an initial discussion.

START A PROJECT

Have a Component, CAD Model or Early-Stage Concept?

Send us what you have. Our manufacturing team will review the geometry, tooling route, expected volumes and the most suitable next step.

info@customcarbonsolutions.com

NDA available before confidential files are shared.