Composite Product Design
Composite Product design from tooling to production.
When is the last time you partnered with a vendor which was willing to take your project from conception to final package design? Does your current composites vendor offer innovative tooling options that will expedite the creation of your product? We know your prototyping requires a limited production run in a very short timetable; in response we offer our digital prototyping services.
We specialize in the extremely difficult and the nearly impossible composite structures.
- Digital modeling to explore conceptual designs at minimal cost
- Rapid turn-around from digital model to Aluminum Tooling
- Low Cost, Structural SLS Prototypes, 3-5 day turn around is common.
- Affordable Large Format CNC mold creation with +/- .005 tolerances
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Carbon by Design
Building Strategic Partnerships
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More important than the products we build, are the alliances we form with our manufacturing customers. We invite you to challenge our abilities, to let our creativity drive your next program. Conventional composites boundaries are broken daily in our facility.
Our answer to your needs includes, rapid tooling, advanced cored structures and meticulous digital design. We have in-house large format CNC capability to bring your project to life, whether it be a small hatch or fully assembled aircraft control surface.
Let us show you how we can help you design and manufacture your next composite program more effectively with a little help from technology. Please contact our engineering team for more information.
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Our Customers Include:
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- Military/Department of Defense
- Aviation/Aerospace
- Automotive OEM/Aftermarket
- Sand Rail and Off-Road Markets
- Boat and Yacht Manufacturers
- Musical Instrument Manufacturers
- Recreational/Sport Industries
 Please contact us to discuss you design needs.
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Processes
In addition to our patented manufacturing process we offer prepreg, trapped rubber, vacuum bag, and infusion and high pressure press laminates
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PRIM
Our proprietary process starts off much like a common hand-laid part, then after lay-up hydraulic pressure is used to force excess resin into a secondary material through a one way permeable layer. This process offers the strength of a VARTM product at the price point of a hand-laid product.
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VARTM
Commonly known as "vacuum infusion" is the predominant way of infusing a product under negative atmosphere. This process offers a solution in many circumstances where compression & tensile values are a primary concern. Our VARTM parts retain 70% the properties of an autoclaved part without the autoclave!
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Aerospace Structures
Carbon by Design has manufactured numerous composite structures which were once considered impossible and slated for redesign. Many programs once though impossible or improbable at reasonable manufacturing costs have been developed by our engineers, saving our customers millions in preventing costly redesigns.
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Flight Control Surfaces
Wing cuffs, rudders, elevators and spoilers are among the flight control surfaces we haves supplied to tier one aerospace customers. CBD has manufactured both honeycomb and foam cored flight control structures.
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Electrical/Avionics Cases
Avionics, radar electronics, film and sensitive digital data enclosures are a specialty of Carbon by Design. Current programs are support the Predator Drone and several DOD high altitude surveillance programs.
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Reflectors/Radomes
Carbon by Design has manufactured EFI/EMI resistant and transparent radomes for L3, Lockheed, Boeing and several other Defense Contractors. CBD manufactures it's own line of sealed (nitrogen-inert) FLIR and Camera housings.
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 For more materials visit our Manufacturing Page. |
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| Digital Product Creation |
Our engineering staff will design your product based upon your program requirements. The Carbon by Design engineering team will conduct an introductory conference call to fully understand your programs scope in order to get your project up and running in no time!
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| Aluminum Tools |
High-tolerance, precision parts often require aluminum or invar tooling. Both of these materials will return extremely accurate products every production cycle. Often tolerance of +/- .001" can be achieved using these tools.
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| Design Validation |
We provide our customers with full stress and design analysis to determine the best possible way to manufacture their product. Our software modeling allows us to determine any potential problems long before any tooling is created.
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