Composite prep refers to the process of preparing materials for composite manufacturing or the assembly of composite products. Composites materials are made from two or more distinct substances, typically combining a reinforcement (like fibres) with a matrix (such as resin), to achieve desirable properties like strength, lightweight, and corrosion resistance.
The composite prep process typically includes several steps beginning with material selection, cutting and shaping, surface preparation and layup.
At The Exact Group, we have over 30 prep stations within the facility, and they are in operation 24/7.
We specialise in both large volume contracts and rapid response niche short run projects for trade shows and prototypes etc.
Composite prep is a crucial step in industries like aerospace, automotive, sports equipment, and construction, where lightweight, durable, and high-performance materials are required.
The key benefits of composite prep:
- Proper preparation ensures optimal bonding between the resin and reinforcement, resulting in composites with superior strength-to-weight ratios, durability, and flexibility.
- By selecting and preparing the right materials, composite prep helps achieve the desired performance characteristics, such as resistance to corrosion, heat, and fatigue, making composites ideal for demanding applications like aerospace and automotive.
- Accurate cutting, shaping, and surface preparation lead to high-quality, defect-free composite products, which are essential in industries like aerospace, where safety and precision are critical.
- Proper prep reduces the likelihood of issues and defects like delamination, poor adhesion, or air pockets, which can compromise the strength and integrity of composite materials.
- Effective preparation can streamline the manufacturing process, leading to faster curing and reduced cycle times in composite production.
- Composite prep allows for the tailoring of materials, including fibre orientation and resin selection, to meet specific performance and aesthetic requirements for a wide range of applications.
- Properly prepared materials reduce waste, minimise rework, and ensure consistent product quality, contributing to cost savings in the long term.
- Composite prep helps create parts that are both lightweight and strong, which is especially important in industries like aerospace, automotive, and sports equipment, where weight reduction is crucial.
The industries that use composite prep:
- Aerospace and Space: Composite prep is essential for manufacturing lightweight, high-strength components like aircraft wings, fuselages, and engine parts that require precise material properties for performance and safety.
- Automotive: Used for producing lightweight, durable parts such as body panels, bumpers, and interior components, helping reduce vehicle weight and improve fuel efficiency.
- Marine: Composite prep is used to create strong, lightweight boat hulls, propellers, and other marine structures that resist corrosion from saltwater.
- Energy: Composite prep is critical in manufacturing parts like wind turbine blades, which require strength, flexibility, and resistance to environmental stresses.
- Oil and Gas: In this industry, composites are used for producing components such as pipes, tanks, and valves, which must withstand harsh environmental conditions, including corrosion and high pressures.
- Defence and Military: Composites are used for lightweight, high-strength parts in defence applications, such as armour, drones, and vehicles, where performance and durability are critical.
- Medical Devices: Composites are used for making prosthetics, orthotics, and medical equipment, providing strength and biocompatibility while keeping devices lightweight.
