CNC Composite Components and Tooling Services

Complementing our 5-axis CNC machining department, Penta Pattern & Model offers high-quality composite components and advanced composite tooling solutions at our Hinckley, Leicestershire factory. Equipped with state-of-the-art technology and a dedicated, highly skilled team, we ensure precision and excellence in every project.

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Materials We Process

At Penta Pattern & Model, we specialise in processing a variety of prepreg materials, including:

• Carbon fibre, available in various colours
• Kevlar
• Fibreglass
• Flax, a new greener composite alternative

All of our materials are stored in our large walk-in freezer. This ensures that rolls of prepreg material are kept at a minimum of -18°C, preserving their integrity.

Our ability to manage all production aspects in-house allows us to maintain complete control throughout each development and manufacturing stage.

We feature two dedicated temperature-controlled clean rooms with fully equipped workstations, enabling us to supply a genuine turnkey service for almost any composite requirement.

The COMPOSITE COMPONENTS AND TOOLING Manufacturing Process

Kit Cutting

We cut materials to shape using our conveyorised kit cutting machine. The latest nesting software optimises material usage, reducing waste while maintaining aesthetic and functional fibre orientations. Kit-cutting is also available as a standalone service if needed.

Laminating

Our specialist laminators inspect the mould surface and each ply for imperfections before laying the plies into the mould methodically. They continue this process until achieving the required thickness with local area plies, bootlace strips, and inserts as necessary.

Vacuum Bagging

After laminating, moulds are wrapped in release film and breather cloth before being carefully placed into a vacuum bag. Air is expelled through a vacuum connector, pulling the composite material closer to the mould surface, and creating better consolidation.

Curing

The bagged moulds are placed into one of our autoclaves – either the Ø1.5m x 3m Italmatic autoclave or the Ø500mm x 1200mm(L) Dwell 280 autoclave – for a pressurised cure. During this process, the resin heats up, flows across the mould surface, and hardens into a solid state. We also offer autoclave cure cycles as a standalone service if required. For out-of-autoclave systems and post-curing, we use a large curing oven measuring 2.5W x 2H x 2.1D.

Demoulding

After curing, composite components are removed from the vacuum bagging, carefully extracted from the mould, inspected, and sent to finishing. The mould is then cleaned and prepared for reuse if necessary.

Finishing

The final stages of the composite process occur in our fully extracted finishing department. Here, cured parts are delicately trimmed to their final shape using air-powered grinders, diamond-coated discs, and other specialist equipment.

If bonding is required, our team uses various fixturing and structural adhesives to accurately bond components and assemblies in our dedicated bonding room.

For parts requiring spray coating or lacquering, we offer in-house services at our factory. Gloss, matt, and satin finishes are available, along with lacquering in a range of colours. Our spraying services extend beyond composites, covering various applications.

Why Penta Pattern & Model for COMPOSITE COMPONENTS AND TOOLING?

We specialise in laminating various composite materials and we are able to meet diverse requirements. Our dedicated clean rooms and skilled team enable us to provide machined composite components of the highest quality. From kit cutting and laminating to vacuum bagging and curing, every step is meticulously managed to ensure excellence.

Our composite tooling process includes cutting-edge techniques and materials such as carbon fibre, Kevlar, fibreglass, and flax. We maintain rigorous standards, ensuring that each composite component meets our stringent quality criteria.

For those needing composite manufacturing services, Penta Pattern & Model offers a turnkey solution, managing everything in-house to maintain control and quality. Explore our services to see how our expertise in composite components and advanced composite tooling can benefit your projects.

    TALK TO THE EXPERTS

    Established in 1985, we have built a strong reputation for manufacturing excellent products within tight timescales and to extremely high tolerances. In order to achieve this, we use state of the art equipment and traditional, time honoured processes and skills.

    Call us on:
    01455 890 571

    Email us at:
    sales@pentapatterns.co.uk