Abstract visualization of a Finite Element Analysis (FEA) mesh on a complex carbon fiber part, showing stress contours in blue and red.

Engineering Lighter, Stronger Structures

We leverage advanced simulation and design expertise to unlock the full potential of carbon fiber, replacing heavy metal components with optimized composite solutions.

Discuss Your Design Challenge

The Metal-to-Composite Advantage

Problem: Metal Components

Heavy-looking industrial metal assembly with multiple bolted and welded components. — Traditional heavy metal assembly

High Mass
Corrosion Risk
Fatigue Prone
Complex Assembly

Solution: Engineered Composites

Sleek, single-piece carbon fiber structural component with complex curves, showcasing advanced manufacturing. — Optimized carbon fiber equivalent

Significant Weight Savings
Superior Corrosion Resistance
Excellent Fatigue Life
Part Consolidation

Our Design & Analysis Toolkit

Finite Element Analysis (FEA)

Simulating stress, strain, and deflection under various load cases to predict performance and failure modes specific to composites.

Laminate Optimization

Using specialized software to define the optimal ply orientation, thickness, and material for each section of a part, maximizing stiffness-to-weight.

Topology Optimization

Employing algorithms to identify the most efficient material layout for a given design space and load path, creating organic and highly efficient structures.

Design for Manufacturing (DFM)

Integrating manufacturing constraints (e.g., draft angles, fiber drapability) directly into the design process to ensure a repeatable and cost-effective part.

Case Study: Aerospace Bracket Redesign

Challenge:

An OEM needed to reduce the weight of a 2.5 kg machined aluminum avionics bracket without sacrificing stiffness or performance in critical aerospace applications.

Process:

Our engineering team performed comprehensive FEA on the original aluminum part to understand its load paths and critical stress points. We then utilized advanced topology optimization algorithms to redefine the most efficient material distribution for the given constraints. Based on this, we designed a new laminate schedule using high-modulus unidirectional carbon fiber, carefully considering ply orientations and drapability for manufacturing.

FEA stress plot visualization on a high-performance aerospace component, showing stress distribution. — FEA stress analysis of the original and optimized design

Result:

Render of the original machined aluminum aerospace bracket.

Original Machined Aluminum Part (2.5 kg)

Photo of the final carbon fiber aerospace bracket, lightweight and optimized.

Final Carbon Fiber Component (1.4 kg)

The final composite bracket weighed only 1.4 kg, a astounding 44% weight savings, while simultaneously increasing stiffness by 15%. This optimized design significantly enhanced the aircraft's performance metrics where every gram counts.

Leveraging Industry-Standard Tools

Start Your Design Journey

Whether you're starting from scratch or converting an existing part, our engineers can provide the analysis and design expertise to make your project a success.

Next Steps:

Schedule a free initial consultation
We sign a mutual Non-Disclosure Agreement (NDA)
We develop a formal Statement of Work (SOW)

Schedule an Engineering Consultation