Rock West Composites | Capabilities

At Rock West Composites, we specialize in the production of carbon fiber tubing.  We have three distinct processes available to produce tubing so you can rest assured we will not try to sell you one process over the other unless truly there is an advantage with one.  Whether it's a simple tube or a very complex, highly engineered structure, we have the experience and engineering background to recommend and produce the most economical solution for your unique application.

In addition to tubing, we also design and manufacture Flat Panels, Sandwich Structures, Cored Structures, Rods, and Bonded Assemblies.    

Manufacturing Processes
   

Roll-Wrapping - Tubing

Sheets of pre-impregnated fibers called "pre-preg" are wrapped onto a mandrel in multiple layers and angles, externally pressurized, and then heat cured to solidify.  After curing, the solid composite form is extracted from the mandrel as a tube.  Rock West Composites has vast experience and know-how with the roll-wrapping process and takes pride in our un-matched quality and efficiency.  Roll-wrapping is primarily used for producing small to medium diameter tubes of shorter lengths -- 0.250" thru 12"dia. -- up to 8' lengths.  Roll-wrapping is typically the most economical process for smaller quantity production runs.

Filament Winding -- Tubing, Tanks, Pressure Vessels

Continuous strands of dry fibers are impregnated with epoxy resin (in situ), wound onto a mandrel via precise CNC control at various angles, externally pressurized for compaction, and then heat cured to solidify. After curing, the solid composite form is extracted from the mandrel as a tube.  In the case of a tank or other closed end vessel, the mandrel could be left insid the composite form or dissolved out via various methods.  Filament winding is best suited for medium to large diameter parts of longer lengths -- 1" thru 24" dia. -- 10' to 20' lengths.  Filament winding is the most automated process for producing tubing and tanks and is best suited for higher quantity production runs.

Bladder Molding -- any Hollow Structure other than a simple tube

Sheets of pre-impregnated fibers called "pre-preg" are wrapped around an inflatable bladder and then placed inside a mold cavity.  Once the mold is closed, pressure is applied to the inside of the bladder causing the bladder to expand pushing the pre-preg outward against the inside of the mold cavity.  Heat is then applied to the mold to solidify or "cure" the composite in the shape of the inside of the mold cavity.  After curing, the mold is opened revealing the hardened hollow structure at which time the bladder is removed (typically) from the inside of the cured part.

Compression Molding -- Plates, Panels, Solid Core non-tubular Structures

Sheets of pre-impregnated fibers called "pre-preg" are compressed between two heated platens inside a mold cavity to simultaneously consolidate and heat cure for solidification.  Compression molding (or Press Molding) is often used to produce flat plate "laminates" or other nearly flat shaped structures.

Bonding / Bonded Assemblies -- specializing in bonding composite to metal components

When executed correctly, bonding of composite assemblies can result in a structure that is as strong or stronger than a welded metal structure.  The bonding process, however, can be a daunting undertaking to someone unfamiliar with adhesives and adhesive chemistry.  Rock West Composites has extensive experience and background bonding assemblies and will either assist you in your own endeavors or will provide the bonding and assembly process for you.