Delivering Composite Solutions with Highest Precision
Manufacturing Processes That We Use
Our strength lies in the design and engineering of complex composite and FRP components, supported by deep expertise in materials and manufacturing technologies. This enables us to function as a reliable partner for diverse industry requirements, including advanced composites India OEM solutions and India composite parts export OEM capabilities.
We utilize a wide range of proven manufacturing processes such as Controlled Hand Lay-up, Vacuum Infusion, VARTM, Vacuum Bagging using Prepregs, Filament Winding, and Compression Moulding to produce high-performance components across sectors, including demanding areas like composites in defence applications India.
1. Hand Lay-up Process
The products manufactured through this process follow the steps below :
Spray Gel Coat
Gel coat provides the required surface smoothness and finish to the product. It is a thin resin layer applied in microns on the surface. With the addition of pigments, the desired color is achieved. This layer also acts as a protective barrier, preventing fiberglass from exposure to water and chemicals.
Surface Mat Layer
A surface mat layer is placed beneath the gel coat to enhance crack resistance and improve the impact strength of the resin layer.
Glass Fiber Laminate
Resin-wetted glass fiber layers are applied sequentially until the desired thickness is achieved. This process, known as lamination, provides the product with structural strength and rigidity. Materials such as chopped strand mat (CSM), woven roving, and uni/bi-directional mats are used depending on strength requirements.
Surface Mat Layer / Resin Coating
Since fiberglass laminate results in a relatively rough surface, a final surface mat or resin coating is applied. This is further refined using a thin Mylar layer to achieve a smoother and more uniform finish.
2. Light Resin Transfer Molding (LRTM) Manufacturing Process
LRTM is a vacuum-assisted resin transfer process that delivers superior laminate compression, a high glass-to-resin ratio, and excellent strength-to-weight characteristics. This makes it ideal for applications requiring both structural performance and surface quality.
In this process, reinforcement materials such as mats or woven roving are placed inside a closed mould, which is then clamped securely. Catalysed, low-viscosity resin is injected under pressure, displacing air and ensuring complete filling of the mould cavity. This controlled process results in consistent part quality and dimensional accuracy.
Key Benefits :
- High-quality cosmetic finish on both sides with consistent thickness.
- Improved strength-to-weight ratio due to optimized resin distribution.
- Faster cycle times leading to cost-effective production.
- Reduced air entrapment ensuring better structural integrity.
Technical Specifications :
- Fire & smoke standard compliance: NFF 16-101.
- Smooth surface finish on both sides, suitable for rail side wall applications.
- Use of polyester-grade gel coat and resin, along with polyurethane-based paint.
- High-gloss finish with gloss levels exceeding 90%.
- Special-grade glass fiber with polypropylene core mat for enhanced performance.
3. Filament Winding Manufacturing Process
Filament winding is a precision-controlled process used to manufacture high-strength fiberglass components with minimal voids and superior structural integrity. This method enables accurate fiber placement, ensuring optimal load distribution and performance across the final product.
With the ability to achieve a high fiber volume ratio of up to 80%, filament winding delivers exceptional strength-to-weight characteristics. The process is particularly suitable for applications requiring uniformity, repeatability, and enhanced mechanical properties in composite structures.
