Composite prototyping opens up a world of possibilities, allowing initial ideas to become reality. The sky’s the limit, from aerospace and automotive parts to space exploration components. In this post, we will explore the process of composite prototyping, its advantages, challenges, and the latest industry examples.
As leading composite manufacturers at the forefront of composite technology, we share our best practices for composite prototyping and insights into future trends.
Table of Contents
What is Composite Prototyping?
Composite prototyping is the process of creating sample components or models using composite materials. Composite materials are formed by combining two or more different materials to create a new material with superior properties. Composite prototyping enables manufacturers to test components on a small-scale, before large-scale production.
The Importance of Prototyping in Advanced Composites
Prototyping acts as a bridge between theoretical design and practical application. This stage is essential for several reasons:
- Performance Validation: Prototyping with advanced composites allows for the testing of materials under conditions that mimic real-world applications. It’s one thing to predict performance through simulations and quite another to observe how a composite behaves under physical stress, temperature variations, or environmental exposure. This validation process ensures that the final product will meet the demands of its intended use.
- Design Optimisation: Through prototyping, engineers and designers can identify potential issues and areas for improvement in the design phase, reducing the risk of costly changes during full-scale production.
- Cost and Time Savings: Prototyping with advanced composites can lead to significant cost and time savings. Identifying design flaws or performance issues early in the development process prevents expensive modifications later on in the production line. It also allows for the testing of different materials and manufacturing techniques to find the most cost-effective solutions.
- Innovation and Customisation: Prototyping enables the exploration of new material combinations and manufacturing processes, which can lead to groundbreaking products that are customised to meet specific requirements.
The Process of Composite Prototyping
Composite prototyping has four stages: design and simulation, material selection, mould preparation and fabrication techniques. Processes such as lay-up, curing and consolidation and demoulding and trimming fall within these categories. Let’s explore these in more detail.
Design and Simulation
The process begins with idea generation. Skilled designers and engineers work closely with clients to translate ideas into tangible designs. Factors considered include the product’s purpose, functionality, aesthetics, manufacturability, and problems it aims to solve.
Then, detailed designs are created using advanced CAD (computer-aided design) software, incorporating the specific composite materials. This stage may also involve FEA (Finite Element Analysis) to simulate the design’s performance under various conditions.
Material Selection
Composite materials are selected based on the final product’s required features. These features include strength, stiffness, weight, reaction to extreme temperatures and environmental resistance. The choice of materials significantly impacts the prototype’s performance and cost. Here is a table comparison of composite material examples, along with their advantages and disadvantages.
| Composite Material Type | Advantages | Disadvantages |
| Fibre-Reinforced Polymers (FRPs) | High strength-to-weight ratioHigh levels of corrosion resistanceMouldable properties | Relatively high costSusceptibility to impact damage, which might not always be visibleLimited recycling options |
| Carbon Fibre Composites | Exceptional strength and stiffness with low weight.High-temperature tolerance and thermal conductivity.Good fatigue resistance. | High cost, limiting its use to high-performance sectors.Conductivity can be a disadvantage in electrical insulation applications.Difficult to recycle. |
| Glass Fibre Composites | Good strength-to-weight ratio (but not as high as carbon fibre). Less expensive than carbon fibre.Good chemical resistance and can be made to be translucent. | Heavier than carbon fibre.Lower stiffness compared to carbon fibre. Prone to wear and abrasion over time. |
| Aramid (Kevlar) Composites | Excellent impact resistance and toughness.Good resistance to abrasion and cutting.High tensile strength, making it suitable for ballistic protection. | Difficult to cut and machine due to its toughness.Relatively expensive compared to other fibres like glass.Absorbs moisture, which can affect its mechanical properties. |
| Natural Fibre Composites (e.g., Hemp, Flax, Jute) | Renewable and environmentally friendly.Lower cost compared to synthetic fibres.Good insulation properties and safer handling due to their natural origin. | Generally lower strength and durability compared to synthetic fibres.Sensitivity to moisture can affect stability and strength.Variability in properties due to natural growth conditions. |
Mould Creation and Preparation
A mould or tool is designed and manufactured to shape the composite material. The complexity of the mould depends on the design of the prototype. In some cases, additive manufacturing (3D printing) can be used to create the mould, especially for complex shapes.
Fabrication Techniques
The composite materials are then placed into the prototype mould, either by hand or automated machinery – this is known as lay-up. Materials are layered according to the design specifications. Once the layers are in place, the assembly is cured under controlled temperature and pressure conditions. This process solidifies the matrix and forms a solid composite structure. Techniques used during this curing process include vacuum bagging, autoclaving and resin transfer moulding (RTM).
After curing, the prototype is removed from the mould. Excess materials are trimmed, and the prototype is brought to its final shape. Surface finishing treatments may also be applied to meet aesthetic of functional requirements. These treatments include painting, polishing and the application of protective coatings.
Advantages of Composite Prototyping
Composite prototyping supports performance validation and design optimisation. It also enables custom products to be launched quickly and efficiently without having to backtrack and make changes at the later stages of manufacturing.
Strength-to-Weight Ratio
Composite materials offer exceptional strength-to-weight ratios, which is important for industries such as aerospace, automotive, military, and defence. This strength-to-weight ratio enhances product performance, aerodynamic properties, and fuel efficiency. By combining high-strength fibres like carbon or glass with the lightweight properties of polymer matrices, prototypes can be created that are strong, durable, and remarkably light.
Customisation and Flexibility
Composite prototyping also enables a world of possibilities; the versatility of composite materials enables a flexible and fully customisable approach to product design. Physical and mechanical properties can be adjusted to meet specific design requirements, such as adjusting the type of reinforcement fibre, changing the resin matrix composition and modifying the orientation of fibres within the composite. This level of customisation enables the creation of prototypes with optimised performance characteristics, such as tailored thermal conductivity, specific electrical properties, or unique aesthetic qualities.
Speed to Market
Composite prototyping streamlines the development process and allows for rapid progression from design to final product. Whilst a prototype may need to undergo various simulations and tests, plus refinements, this process enables the final product to go into mass production with confidence and speed. This shortens the product development cycle and enables companies to respond to current market demands.
Challenges in Composite Prototyping
While composite prototyping has many advantages, factors to consider include costs, technical challenges, and testing and validation.
Cost Considerations
The benefits of superior strength-to-weight ratios and customisability can come with higher manufacturing costs. Specialised materials such as carbon fibre can be more costly, as can the need for specialised tooling and skilled labour for fabrication and assembly.
Initial costs may appear particularly high in the prototyping phase, where multiple versions may be required to refine the design. This can be a barrier for some start-ups and smaller enterprises. Therefore, initial costs must be weighed against the potential value of the product’s success.
Technical Challenges
Various technical challenges may present themselves in the process of composite prototyping. These include:
- Achieving uniform material properties: Variations in fibre orientations, resin distribution and curing conditions can lead to inconsistencies.
- Defects such as voids, delamination and warping: Fabrication techniques such as lay-up, vacuum bagging and resin infusion require a high level of expertise to avoid these defects.
- Joining composite materials parts to other materials: Innovative solutions may be needed to ensure structural integrity and performance.
Overcoming these technical challenges requires a deep understanding of composite materials science and advanced engineering techniques. These challenges also highlight the need for skilled professionals and investment in research and development.
Testing and Validation
Mechanical testing is needed to validate the strength and durability of a composite prototype. This may include tensile, compression, and flexural tests, as well as impact and fatigue tests. Environmental testing is also important to assess the prototype’s resistance to factors such as temperature extremes, moisture, UV exposure, and corrosive environments. Other non-destructive testing techniques, such as ultrasonic inspections and X-ray imaging, may also be used to detect internal defects or delaminations without damaging the prototype. These testing processes can be challenging in terms of time, energy and costs.
Industry Examples of Composite Prototyping
Composite prototyping is used across a variety of sectors, including aerospace, automotive, drones and UAVs, renewable energy, space, motorsport, medical, marine and technology. Let’s take a look at some real-life examples of prototypes in aerospace and automotive applications.
Aerospace Application
A successful example of composite prototyping in aerospace is the VX4 prototype, an aircraft designed to produce minimal noise and zero in-transit emissions. In September 2022, the first VX4 model began a series of test flights. After an unfortunate unmanned crash in 2023, the second VX4 prototype began development.
The second prototype is said to be more ‘sophisticated, faster and quieter’ and features second-generation propellors. These propellors were developed after the blade failure of the first prototype. In this case, the first prototype was not a failure, it was the gateway to a new and improved model before going into real-life manufacturing and service. This is a prime example of how composite prototyping can save valuable time, energy and money.
Automotive Innovation
Another success story in the automotive industry is the Apache APH-01. This automotive prototype is a high-performance, hybrid rally race car that operates on second-generation biofuels and uses bio-based composite materials in its bodywork. During the development process, APACHE Automotive trusted VESO Concept to produce prototypes and refine structural reinforcements, polymer blends and production processes.
After one year, the first prototype was delivered in the form of two vehicles. In January 2024, both prototypes performed highly in the 15th Edition of the Africa Eco Race – one winning first position. This demonstrates how the prototyping process can reap huge rewards and produce top-performance vehicles.
Best Practices for Composite Prototyping
Adopting best practices maximises the benefits of the prototyping process whilst mitigating challenges. This can be achieved through using advanced technologies and by collaborating with experts in the field.
Leveraging Advanced Technologies
Using technologies such as computer-aided design (CAD) and finite element analysis (FEA) can predict performance issues and material behaviour. This reduces the need for extensive physical testing and is best practice when developing a product. Other technologies that can be used include manufacturing techniques such as resin transfer moulding (RTM).
However, it is best practice to evaluate which methods are most appropriate for specific designs. For example, hand lay-ups may be effective for simple prototypes, but advanced methods such as RTM may be needed for more intricate designs.
Collaboration and Expertise
Other best practices include collaboration across expert teams, which may include material scientists, designers, technicians, and engineers. This type of collaboration enables innovation and problem-solving at its highest level. It also supports the quality control process during each stage of the manufacturing process.
The Future of Composite Prototyping
The future of composite prototyping is full of possibilities. With the integration of artificial intelligence (AI) and machine learning (ML), the prototyping process is set to revolutionise design optimisation, predictive performance modelling and automated manufacturing processes.
Emerging Trends
Emerging trends include smart composites, bio-based and recycled composite materials and advanced manufacturing techniques. Smart composites incorporate sensors or IoT (Internet of Things) capabilities directly into the material. This is set to revolutionise how prototypes and final products interact with their environments, offering real-time monitoring and adaptive responses to conditions such as stress, temperature, and humidity.
Plus, the integration of advanced manufacturing techniques, such as 3D printing with continuous fibre reinforcement, opens new avenues for creating prototypes with complex geometries and optimised material distribution.
Sustainability in Prototyping
The drive towards a more sustainable future is expected to push the development of eco-friendly composite materials and recycling technologies. Bio-based and recycled composite materials are being developed rapidly and aim to reduce environmental impact without compromising performance.
Summary
Composite prototyping is the process of creating sample components from composite materials, and it has many advantages in various industries. These advantages include design optimisation, performance validation, time and cost savings, and the ability to create completely customised products. Ultimately, these advantages enable composite-based designs to be launched with confidence, efficiency and speed.
At Piran Composites, we have extensive knowledge of composite manufacturing processes and incorporate Design for Manufacture (DFM) principles into our designs. This ensures that we deliver top-performance, cost-effective products with precision. It also allows us to scale a prototype for mass production, following successful testing procedures.
