Composite Manufacturing

Pre-Impregnated

The pre-impregnated manufacturing process involves the use of carbon fiber cloth that has been pre-impregnated with resin. This resin is partially cured, ensuring that it is in an ideal state for creating high-performance, precise, and durable carbon fiber components. Pre-impregnated carbon fiber cloth is applied to the mold according to the required specifications.

Depending on the application, the pre-impregnated part is cured through an autoclaving process or at an elevated temperature. This results in superior mechanical properties, uniformity, and strength, making it ideal for high-performance applications. Pre-impregnated technology is used for the most demanding components in the aerospace, automotive, and racing industries.

Vacuum Infusion

Vacuum Infusion, also known as Resin Infusion, is an advanced process where resin is introduced into dry carbon fiber cloth under vacuum. This process begins with laying up dry carbon fiber cloth in a mold and sealing it with a vacuum bag. A vacuum is then applied to remove air, compress the fibers, and create a controlled environment. Resin is drawn through the fibers, saturating them completely without voids or inconsistencies.

After curing, the result is a flawless composite with enhanced structural integrity and superior mechanical properties. This method ensures a highly controlled resin-to-fiber ratio, producing lighter, stronger, and more consistent composite parts. The curing temperature varies depending on the required performance of the component.

AMC Composites utilizes this process to deliver high-quality composite solutions tailored to exacting performance standards, ensuring reliability and innovation in every component. Vacuum infusion is ideal for applications requiring cost-effective yet high-performance solutions, most commonly found in the automotive, marine, and industrial sectors.

Wet Layup

Wet Layup is a traditional and versatile carbon fiber manufacturing method where dry carbon fiber cloth is impregnated with liquid resin as it is applied directly into the mold. The process involves manually saturating the reinforcement material with resin and layering it into the mold, ensuring good adhesion and structural integrity.

This hands-on approach allows for greater flexibility in handling unique shapes and custom designs, making it an excellent choice for larger parts, prototype development, and low-volume production runs. The wet layup method is ideal for projects where high precision or performance characteristics are not the primary requirements but where durability, functionality, and affordability remain key considerations.

It provides a fast and cost-effective solution, especially for applications focusing on simplicity and practicality over cutting-edge performance. Additionally, it enables rapid iteration during prototyping, allowing designers to refine their concepts with minimal delays.

Forged

Our Forged Carbon Fiber process combines advanced technology with the strength and lightweight properties of carbon fiber, creating a highly durable and aesthetically unique part. This innovative method involves mixing chopped carbon fiber with resin to create a malleable mixture, which is then compressed under elevated temperature and pressure.

The result is a durable composite that retains the exceptional performance characteristics of traditional carbon fiber while offering unmatched versatility in design and manufacturing. Unlike woven carbon fiber, the random orientation of fibers in forged carbon allows for complex geometries and shapes to be molded with ease. This makes it ideal for applications requiring unique designs or intricate features without compromising strength or weight.

The process is particularly efficient for large-scale production of small to medium-sized components, offering significant cost advantages over traditional carbon fiber manufacturing. Forged carbon fiber stands out as our most cost-effective large-volume production method.

This affordability, combined with its excellent mechanical properties and distinctive visual appeal, makes it a valuable solution for industries ranging from automotive to consumer goods. Whether you need high-performance components or visually striking designs, our forged carbon fiber process delivers on all fronts.

Additive Manufacturing (3D Printing)

The process of 3D printing carbon fiber is a type of additive manufacturing that utilizes cutting-edge extrusion technology to create strong, lightweight, and highly customizable parts directly from digital designs. By combining carbon fiber with advanced thermoplastic resins, we produce composite components with exceptional mechanical properties, complex geometries, and rapid prototyping capabilities.

This manufacturing approach offers outstanding versatility, making it ideal for applications requiring rapid prototyping and low-volume production. It is commonly used in aerospace, automotive, and industrial sectors where intricate designs would be difficult or impossible to achieve using traditional manufacturing methods.

The ability to modify designs in real-time and create optimized structures—such as lattice frameworks, hollow sections, or geometrically complex features—adds significant value. Additionally, this process enables the production of performance-critical parts with superior strength-to-weight ratios, tailored to meet specific engineering requirements, all while reducing material waste compared to conventional techniques.

Kevlar

For applications where the full performance of carbon fiber is not necessary, Kevlar serves as a cost-effective and versatile alternative, offering lightweight strength and durability. Using manufacturing processes similar to carbon fiber, such as vacuum infusion and wet layup, we produce Kevlar components with exceptional precision and repeatability.

Kevlar’s unique properties—including high tensile strength, abrasion resistance, thermal stability, and impact resistance—make it ideal for components requiring superior toughness and protection. In aerospace, it is used for lightweight panels and protective linings. In the automotive sector, it plays a key role in impact shields and reinforcements. The military relies on Kevlar for bulletproof vests, helmets, and vehicle armor. Sporting goods manufacturers leverage Kevlar’s strength and resilience for high-performance equipment such as paddles, rackets, and protective padding. Kevlar ensures reliable performance even in the toughest environments.