Production Methods

Our skilled production team uses various techniques to serially produce high-quality composite parts. These methods ensure precision, consistency and efficiency throughout the production process, resulting in high-quality composite solutions. This allows us to meet the diverse needs of our customers in various sectors, including aerospace, mechanical engineering, UAV, defence and mobility.

Prepreg lamination

Prepreg lamination is a widely used production process for thin-walled lightweight composite parts. The base material is a fibre pre-impregnated (prepreg) with a resin matrix, within Refitech mostly epoxy. The material is stored in rolls in a freezer to prevent the resin from curing prematurely. The required laminates are cut using a CNC cutting plotter, ensuring that each laminate is the same size for series production. Our composite specialists carefully laminate the prepreg laminates in a mould. The orientation and layering determine the characteristics of the final product. This production method gives the highest achievable fibre volume share in the final product, often around 60 – 65%.

The laminate package is then subjected to heat and pressure under a vacuum to start curing the resin. This is often done in an autoclave, oven or hot press. This process ensures very even resin distribution and adhesion between the layers, resulting in high-quality composite parts with excellent mechanical properties.

Vacuum infusion

Refitech uses this production method to make composite parts with an excellent strength-to-weight ratio. In this process, a dry fabric mat, such as carbon fibre or glass fibre, is placed on a mould or tool. A vacuum film is then sealed tightly over the fibre layers, creating an airtight whole. Resin is then introduced into the mould via a special mixing vessel through pipes and channels in the mould. Due to the vacuum on the film and the mould, the resin is drawn through the fabric, which ensures thorough impregnation. The impregnated laminate is cured at ambient temperature or by heat. Vacuum infusion offers advantages such as surface finish through gel coat, low air entrapment and short production time for large complex moulds.

Assembly & Glueing

We offer professional assembly and glueing services. Whether you need cut-outs for electrical wiring, mounting points for inserts or custom features for special applications, we can accommodate your needs.

Waterjet cutting

With our high-pressure CNC waterjet cutting machine, we are able to accurately cut products with complex patterns and shapes. This cutting method ensures clean and precise cuts.

Engineering

Because the engineering rules for composites differ from those for more traditional materials such as steel and aluminium, companies often involve us at an early stage in the design of innovative products.

RTM-light

RTM-light (Resin Transfer Moulding-light) is a variant of resin transfer moulding, a closed-mould manufacturing process used to make composite parts. In RTM-light, a dry fibre package is placed in a two-sided mould, after which the mould is closed and clamped. Resin is injected under pressure and elevated temperature into the mould cavity through carefully designed feed holes. The resin flows through the mould, impregnating the fibre package and displacing air or excess resin. This process offers us the advantages of shorter cycle times, multiple numbers per run and the ability to produce complex moulds with high dimensional stability and relatively high fibre volume fraction.

Hot press

In hot pressing, composite materials are fixed to each other with compressive force and cured under elevated temperatures to form a product. In this process, prepreg layers are placed on a mould after which the mould is closed and a hydraulic press pushes the mould halves firmly together. The combination of heat and pressure ensures good homogeneity and results in high fibre volume contents for optimum strength and stiffness. Hot pressing offers advantages such as precise control over temperature and pressure that allow impact-strength 2D parts to be made. For 3D moulded parts, this process cannot be used.

Autoclave

This production method offers advantages such as mould-free and thin-walled construction, allows small tolerances and gives a high-quality surface finish. An autoclave is a pressurised booth in which heat and high pressure ensure that the composite material remains positioned in a mould and is allowed to cure. In the autoclave process, the composite composition, which usually consists of prepreg materials, is placed in a sealed bag or vacuum film and placed in the booth. The autoclave is pressurised and tempered in pre-programmed steps to allow the resin matrix to cure. The high pressure in the autoclave ensures that the laminates are strongly pressed together, while the controlled temperature ensures proper resin flow and curing.

Oven

When processing composites, there is always a reaction of temperature and air with the resin matrix. This process is accelerated in a controlled manner by Refitech using an autoclave or an oven. In an oven, a vacuum applied to the laminate provides the pressure and ultimately resin flow and curing. For applications where wall thickness and finish are less critical, ovens are ideally suited. Another difference compared to autoclave curing is the type of composite materials and the mechanical properties of the final product. The final process costs for oven production are also lower than with autoclave. Therefore, from the start of projects, Refitech thinks along with you about these choices to give the most realistic advice.

Composite materials

Each material has unique technical properties and advantages. Discover which materials Refitech can use for your project.

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A reliable and trusted European-based supplier, capable of meeting your diverse requirements, while maintaining a focus on quality, communication and efficient production processes.

Prototype to series production
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Idea to composite solution
ISO 9001:2015 certified

Sluisweg 30
5145PE Waalwijk
North Brabant
The Netherlands
VAT Number: NL806664605B01
Chamber of Commerce Number: 18052319

since 1989

Production Methods

Industrial services

CNC-milling

Assembly & Glueing

Waterjet cutting

Engineering

Knowledge Base

Why choose Refitech?

We are ready to transform your complex ideas into innovative composite solutions.

Refitech Composite Solutions

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