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Composite structures, from laminate to first part.

Wings, panels, chassis and crash structures designed ply by ply, checked with FEA and built as prototypes in our own moulds.

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Services

From first load case to signed-off drawing.

Calculation, laminate, documentation and the training of the people who build it.

StructuresCarbon · Glass · Core

Composite wing & structural engineering

Ply-by-ply laminate design for wing skins, spars and ribs
Classical laminate theory, failure criteria and finite element analysis
Sandwich panels, inserts and bonded joints
Marine structures to ISO 12215 and class rules

SimulationFEA · CAE

Advanced structural simulation

Static, modal and linear dynamic analysis
Vibration, shock and fatigue life prediction
Buckling and post-buckling of shells and panels
Coupled thermal-structural analysis
Drop, impact and collision analysis
Composite damage analysis and laminate optimisation

Automotive & motorsport

Monocoques and crash structures, simulated before the first test.

Composite chassis and energy absorbers have to pass destructive tests the first time. We model stiffness, strength and crash behaviour with implicit and explicit FEA, then design the laminate and the test plan.

Carbon fibre bodywork on a sports car — Monocoque & crash structures

Torsional stiffness · FEA
Monocoque chassis
Torsional and bending stiffness, load paths into suspension and roll-structure hard points, and ply-by-ply laminate optimisation.
Explicit crash · SEA
Impact attenuators
Crushable composite nose cones and energy absorbers sized for mean deceleration, peak load and specific energy absorption.
Explicit FEA
Side impact & anti-intrusion
Side impact panels and anti-intrusion laminates checked against penetration and energy targets.
Fatigue · buckling
Suspension & wishbones
Composite wishbones, push rods and uprights with bonded metal inserts.
CFD loads → FEA
Aero parts
Rear wings, diffusers and floors sized from aerodynamic loads for strength and deflection limits.
Crush · thermal
Battery enclosures
Composite EV battery boxes for crush loads, intrusion and fire-resistant laminates.

Prototyping & tooling

From a drawing to the first part you can test.

We design the part, machine the plug, build the mould and laminate the first articles. You test a real part in your own system before committing to series tooling.

Design
Laminate and geometry sized by calculation.
Plug
CNC-machined master model from your CAD data.
Mould
Composite mould built off the plug, ready for lay-up.
Prototype
First articles laminated to the written schedule.
Test
Fit, function and load tests in your system.
Pre-series
Small batch with a techno-economic case for series production.

Metal to composite

Replace a steel or aluminium part with a lighter composite one: same loads, same interfaces, checked by calculation and confirmed by test.

Questions

Frequently asked questions

Can you replace a metal part with a composite one?

Yes. We start from the loads and interfaces of the existing part, design the laminate and inserts, check it with FEA and build a prototype for testing in your system before any series tooling.

What we do