Composite Components

Established in 2002 with a passion for advanced composite manufacturing, our business has evolved into a global provider of top-tier composite products and solutions, delivering a diverse range of services and products offerings operating at ocean depths of 1000 meters to 20,000 feet in the skies for over 20 years.

We uphold the highest manufacturing standards, leveraging cutting-edge technology to create optimal solutions for our clients with every part we produce reflecting our commitment to achieving world-class quality.

In the composite manufacturing field, we stand out. Unlike larger companies focused on specific product lines, we collaborate with diverse companies and government bodies to bring ambitious ideas to life. Our independence and willingness to tackle complex projects have yielded positive results.

Our client base spans medical, defence, aerospace, automotive, mining (land-based), oil and gas, architecture, and recreational goods. In 2020, we expanded to a new workspace facility in Bibra Lake, Western Australia, doubling our work area. Fully equipped with cutting-edge machinery, we continue to deliver robust solutions. Our accolades include an Australian Design Award and multiple JEC Composite Innovation short listings, fuelling our high expectations for the future.

Production Process:

Our primary manufacturing approach involves hand laminating of pre-impregnated (pre-preg) fabrics—carbon, Kevlar, or glass fibre (or combinations thereof). We complement this with compression moulding and/or vacuum bag oven curing. Additionally, we utilize methods like resin transfer moulding (RTM) and vacuum infusion. These carefully chosen processes yield superior parts due to controlled resin-to-reinforcement ratios, enhancing both performance and aesthetics. 

3D Systems:

Our company boasts 3D Computer-Aided Design (CAD) capabilities using Rhino and SolidWorks. We create precise computer models for various purposes, including parts, master patterns, moulds, and further analysis (such as Computational Fluid Dynamics or Finite Element Analysis). Additionally, we collaborate with clients, updating and refining their 3D models as needed. Our early adoption of this technology has allowed us to build strong relationships with machinists, designers, and engineers, maximizing the benefits of CAD/CAM/FEA/CFD and other computational analyses.

State of the Art Plant and Equipment 

Within our 1500 sqm facility, we allocate over 500 sqm for project assembly. Our temperature-controlled clean room is dedicated to laminating and producing components. For curing, we operate three ovens, with the largest measuring 5m x 2m x 2m and capable of reaching temperatures up to 180°C. High production capacity is further supported by two 100-ton heated hydraulic presses reaching 200°C, featuring platen sizes of 100cm x 60cm x 25cm and 140cm x 40cm x 25cm. These presses enable rapid production of composite parts.

Our preference lies in using pre-preg materials, and our walk-in freezer houses up to 25 rolls of different materials, readily available for various applications. Additionally, we leverage three CNC routers (3, 4 & 5 axis) for precision trimming and machining tasks. Our CNC cutter plotter, measuring 7m x 2m, accurately plots and cuts reinforcement materials based on CAD/CAM software-generated production runs.

Furthermore, our five 3D Fused Deposition Modelling (FDM) plastic printers and SLA machines serve prototyping, master pattern creation, full-size accurate moulds, and scale models.

We also utilise a handheld 3D scanner to precisely map structures and objects for design and metrology purposes.

Research and Development:

Collaborating with composite manufacturers and suppliers worldwide, we source materials for research, development, and manufacturing. This knowledge base directly caters to our clients’ demands for high-quality parts and cutting-edge technology. For structural analysis and optimization, we rely on SolidWorks Composite Simulation FEA. This software allows us to simulate ‘ply by ply’ and ‘whole laminate’ (assembly) scenarios, critically evaluating structures before production. By leveraging composites’ unique capabilities, we optimize weight and performance-critical components for our clients.

Our commitment to continuous improvement includes rigorous testing, archiving, experimentation, and learning. We educate our clients on the latest practices and showcase future manufacturing ideas. Attending industry exhibitions and staying updated through trade magazines ensures that we deliver the most current knowledge and technology.

Ethics:

Confidentiality is paramount as we work closely with our customers, respecting their intellectual property and commercial sensitivities. Composite Components are always looking for good people who want to lead, advance, and enhance our business and are an equal opportunity employer that promotes diversity and social responsibility.