Primary process: Composite Layup / Pultrusion. The full route, materials, tolerances and design tips for a structure, with an indicative cost.
Composite Layup / PultrusionPrimary process
PolymerFamily
6Route steps
+/-0.5mmTypical tol.
A structure is primarily made by Composite Layup / Pultrusion. Composite layup places fibre reinforcement and resin into a mould by hand or machine, then cures it, often under vacuum or in an autoclave, into a stiff light part. Below is the full route to make a structure, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a structure is made
The usual route, raw material to finished part. The amber step is where the structure gets its basic shape.
Material
Select the fibre, resin and core for the structure.
Composite Layup / Pultrusion
Lay the fibre and resin into the mould and cure to make the structure.
Tooling Low to medium Tolerance ±0.3 to 1mm Lead 1 to 6 weeks
Trim
Trim the edges, flash and any waste material.
Secondary
Where the structure needs them, add inserts, printed graphics or machined details.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Assembly
Where the structure joins other parts, snap-fit, weld or bond it into the finished product.
Tooling Low Tolerance good Lead immediate
Inspection
Check fit, finish and any functional dimensions.
Need the real cost for a structure? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a structure
Grade
Why it suits this
Glass fibre + epoxy/polyester
Cheap composite, strong
Carbon fibre + epoxy
Very stiff/light
Prepreg
Controlled, autoclave
Design
Design tips
General pointers. The full design-for-manufacturing list for a structure is in the dossier.
Tight radii / sharp corners.Generous radii for drape.
Thick laminate in one cure.Stage cures or de-bulk.
Cost
What a structure should cost
Composite parts (CFRP/GFRP); low volume, high labour and material. Pultrusion is the cheaper continuous cousin.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a structure at your volume, in your currency, are in the dossier.
MODEL EST.
$380 to 1060per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a structure and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
SistematikWork is a whole IE platform. Past the free finder, there are 41 ready Excel calculators, templates and CAD guides, each built from real coursework and checked against known values.
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A structure is primarily made by composite layup / pultrusion. The route is: Material; Composite Layup / Pultrusion; Trim; Secondary; Assembly; Inspection.
What does a structure cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $380 to 1060 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a structure made from?
Common choices are Glass fibre + epoxy/polyester; Carbon fibre + epoxy; Prepreg.
What is the main process for a structure?
Composite Layup / Pultrusion. High strength-to-weight parts: aerospace structures, wings, hulls and sports frames.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
