Composites Manufacturing Consulting

Many aerospace and UAV applications utilize Resin Transfer Molding (RTM) and Vacuum-Assisted Resin Transfer Molding (VARTM) to achieve high-stiffness, lightweight, and swift production. Our consulting services focus on optimizing resin flow, fiber wet-out, and curing cycles to achieve superior mechanical properties and reduced manufacturing defects. Whether you’re refining an existing process or implementing RTM/VARTM for the first time, we provide expert guidance to enhance efficiency, material utilization, and final part performance. 

Autoclave processing is often critical for achieving light-weight, high composite performance, but inefficiencies will lead to high costs and defects. We specialize in cycle time reduction, pressure and temperature uniformity, and curing strategy refinement based on polymer cure kinetics and rheology to ensure consistent, high-quality results. Our team helps manufacturers fine-tune autoclave parameters, reduce energy consumption, and eliminate porosity, leading to improved production throughput and part quality. 

Voids and porosity in composite laminates compromise structural integrity and performance, particularly in mission-critical aerospace and defense applications. We provide data-driven void reduction strategies, leveraging in-situ monitoring, optimized layup techniques, and tailored processing parameters. Our expertise in modeling void mobility and resin flow dynamics helps clients achieve aerospace qualification standards while utilizing the most cost-effective process for their applications.

Tired of writing up the same non-conformance reports (NCRs) in your production line? Unexpected failures in composite components can lead to costly delays and safety risks. Our RCA services combine forensic engineering, process optimization, and material analysis to identify the root causes of composite failures. Whether addressing delaminations, resin dry spots, or interfacial stress fractures, we provide actionable recommendations to enhance durability, reliability, and compliance with aerospace standards. 

Reducing waste and increasing efficiency in composite manufacturing is crucial for cost control and production scalability. We have generated a 50-1000x for OEMs through cutting waste and improving composites yield rate. Our LEAN manufacturing consulting services focus on workflow optimization, process standardization, and nonconformance reduction. We help clients implement continuous improvement strategies that enhance quality, minimize scrap, and shorten production lead times—all while maintaining aerospace compliance. 

Even the best organizations struggle with FOD. Maintaining a contamination-free environment is essential for producing defect-free composite parts. We assist manufacturers in designing and implementing clean room standards, layup protocols, and environmental controls to ensure consistent delivery of aerospace-grade builds. Our expertise spans from airflow management and material storage best practices to static control and technician training, helping clients achieve consistent and repeatable manufacturing outcomes.