Manufacturing processes

 

Composite tubes

Our Composite tubes can be made up of Carbon fibre, Glass fibre or a mix of both and are manufactured using the roLayered tubell wrap method. Described below is a tube of Carbon fibre construction:

This method starts with a precision-machined mandrel around which pre-impregnated carbon fibre material is wrapped creating layers to form the tube. The carbon fibre in these layers can be oriented appropriately to give stiffness and strength where it is desired, tailoring the tube to many applications.

The roll wrapping of the carbon fibre material is followed by a winding process where a cellophane wrap (typically polyester Mylar shrink tape) is carefully wound at a specific tension around the diameter of the tube.  This step is the key to producing a high quality, high performance tube.

Once the tube is wound it goes into an oven for curing.  The elevated temperature causes the shrink wrap to shrink against the mandrel/sleeve which is trying to slightly expand.  The compaction pressures created are enormous which maximizes density and fibre to resin ratio.

Once cured and the cellophane removed, a slight stepped texture remains in the epoxy resin (similar to a rats tail).  This imprint is only about .002"-.003" thick and can be removed easily with a light sand if cosmetics are important.  Once sanded, if the tube is to be clear coated to a smooth glossy finish, the use of polyurethane will provide the necessary UV resistance.

The inside of roll-wrapped tubing is very smooth reflecting the surface finish of the precision-machined mandrels. 

 

Flat plate

Our Composite flat plat can be made up of Carbon fibre, Glass fibre or a mix of both and are manufactured using a vacuum bagging process.

This method starts with a precision-machined flat surface which pre-impregnated composite material is layered to form a plate of the required thickness. These layers can be oriented appropriately to give stiffness and strength where it is desired, tailoring the plate to many applications.