See how we help clients turn ideas into workable designs, learn about selecting the right material, and find out how we support your project.

Do you offer design and engineering support?

• Yes, we work with clients throughout the design process, from early concept development through final production. Our capabilities include CAD modeling, material selection, FEA analysis, and prototyping.

Can my existing CAD part be redesigned specifically for carbon fiber manufacturing?

• Yes, your existing CAD design can often be adapted for carbon fiber, but modifications may be needed to optimize for material properties like stiffness, fiber orientation, and manufacturability.

What design changes are usually needed to make a part compatible with carbon fiber?

• Design changes may include adjusting wall thicknesses, smoothing transitions, minimizing sharp corners, and aligning geometry with the fiber direction for structural efficiency.

How do you ensure the part meets performance goals like strength, stiffness, and low weight?

• We use material selection, layup strategy, and simulation tools to meet your performance goals while keeping the part as light and strong as possible.

Can you design carbon fiber parts that meet aerospace or medical-grade tolerances?

• Yes, we can design parts to meet tight tolerances required for aerospace or medical applications, depending on your specifications.

How do you handle fiber orientation to maximize strength in the right directions?

• We align fiber plies with anticipated load paths, using unidirectional and woven fabrics in tailored sequences to achieve strength where needed most.

What are the limitations when designing complex shapes or thin-walled structures in carbon fiber?

• Complex geometries and thin walls can be challenging due to tooling, layup access, or fiber bridging, but many limitations can be during design and molding.

Can inserts, threaded fasteners, or metal components be integrated into the design?

• Yes, metal inserts, threaded fasteners, and other components can be integrated into carbon fiber parts during the design and manufacturing process.

What kind of simulation or stress analysis do you use to test the design?

• We do not engage in testing or validation of your product. We will gladly refer you to an appropriate testing agency, and provide you with testing samples as part of your prototyping cycle.

What files or information should I provide to get started with part design?

• To get started, please provide a 3D CAD file (STEP format preferred), along with any relevant 2D drawings, material requirements, load conditions, and intended use of the part. If you have target weight, performance goals, or manufacturing constraints, including those details will help us design more effectively.

Can you reverse-engineer an existing metal or plastic part for carbon fiber manufacturing?

• Yes, we can reverse-engineer existing metal or plastic parts and redesign them for carbon fiber manufacturing. To begin, we’ll need the physical part, detailed photos, or 3D scan data, along with information on how the part is used and any performance requirements. This allows us to adapt the design for carbon fiber’s unique properties while maintaining or improving functionality.