WHAT WE DO
OUR RANGE OF COMPOSITE MANUFACTURING SERVICES
Lightning Composites expertise are here to ensure your composite manufacturing project is successfully completed on time and on budget. We will manage your project from start to finish and support you in every way to ensure you are satisfied with the outcome.
Our capabilities extend beyond the manufacturing of composite components, where we have adopted a range of latest technologies such as CNC machining, 3D printing and design consultation. We assure our clients that the latest manufacturing technologies are adopted to ensure the outcome is cost effective, efficient and as desired. We can satisfy your requirements by:
Enhance the design, development and effectiveness of your required composite components.
Support the transition from other materials to composite material construction for optimal performance
Support the development of mold's and composite components to minimise costs.
Support the integration of composite components within the desired application.
Our capabilities extend beyond the manufacturing composite components:
CNC Machining (3-axis)
Compression molding
Vacuum infusion
Carbon fibre CNC machining
Composite panel repairs
Composite design consultation
Design and engineering
Complex mold pattern development and manufacturing
ADVANCED COMPOSITES
MATERIAL SELECTION
We specialise in a range of advanced composite materials. With our material expertise, we can help you determine which is the best material for your application for the best performance. We can offer you a range of the following materials to be used within our vacuum infusion on hand laying processes:
MATERIALS
SANDWICH PANELS
RESINS
Carbon fibre
Kevlar fibre
Fiber glass
Polyethylene (Dyneema)
Basalt fibre
Bio-fibre
Foam core
Core-mat stiffener (soric)
Aluminium honeycomb
Aramid fibre honeycomb
Nomex honeycomb
PVC
Polyester
Vinyl-ester
Epoxy
Polyurethane
We can also cater for a large range of alternative material forms such as exotic carbon fibre weave patterns.
VACUUM INFUSION
We use the vacuum infusion process for a significant portion of our composite parts. This manufacturing process provides excellent quality, consistency, great exterior finish and fast cycle times, all at a lower cost than other composite manufacturing processes.
The resin infusion process consists of a composition of dry materials being filled with a liquid resin which is aided by a vacuum pulling the resin through the material. When this resin solidifies, the solid resin matrix binds the assembly of materials into a rigid composite.
BENEFITS OF VACUUM INFUSION
Lower investment costs
High resin-to-fibre ratio (up to 70% fibre, 30% resin)
Minimal weight , high performance laminates with similar performance properties to cured prepreg composites.
Infusion is a practical and cost effective solution for constructing large, high strength and low weight parts such as hulls and wind turbine blades
Fast cycle time
Low chances of trapped air / voids
CNC MACHINING
CARBON FIBRE CNC MACHINING
We operate with a range of versatile CNC machines, providing you with the ability of having specialised and complex carbon fibre components manufactured in addition to large 3D plugs. Our machines have the capabilities of machining objects within the dimensions of 1200x2500x500.
We can machine a large range of materials as listed below:
MATERIALS
Carbon fibre
Aluminium
MDF
Tooling Board
Plastics
Aluminum composite material (ACM)
For quoting purposes, we require files in a STEP format for 3D components and a DXF for 2D cut-outs. If you require assistance with your CAD drawings, contact our experienced team today.
PRODUCT DEVELOPMENT
Lightning Composites expertise extends well beyond the Motorsport industry, having been involved with infrastructure, industrial manufacturing, medical, marine, defense and electrical. Advanced composite solutions provides innovative opportunities amongst any industry with its fantastic properties consisting of high strength, high flexibility, low fatigue, electrical, thermal and chemical resistance.
Lightning Composites is conditioned to operate in highly competitive and pressured environments, with our products being proven in a diverse range of fields.
We have the capabilities of producing components from the initial idea through to the finished part. With our range of capabilities including CAD design, pattern making, mold making and part building / optimization, we are able to help you achieve your goals and requirements.
