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How Composite Layup / Pultrusion Works

Composite Layup / Pultrusion: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.

PolymerFamily
+/-0.5mmTypical tol.
5Route steps
91Parts in finder

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.

At a glance

When to use it, and when not

Best for

High strength-to-weight parts: aerospace structures, wings, hulls and sports frames.

Watch for

Labour intensive, long cure cycles and part-to-part variation without automation.

Step by step

The typical route

Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.

  1. Mold prep

    Prepare and release-coat the mold.
    Tooling Mold   Tolerance -   Lead -

  2. Lay plies

    Lay the fibre plies to the schedule (hand or machine).
    Tooling -   Tolerance -   Lead -

  3. Cure

    Cure at room temp, in an oven, or autoclave.
    Tooling Autoclave   Tolerance -   Lead -

  4. Trim

    Trim edges and drill.
    Tooling CNC   Tolerance -   Lead -

  5. NDT

    Ultrasonic/tap-test for voids on structural parts.
    Tooling -   Tolerance -   Lead -
Precision

Tolerances it can hold

TYPICAL TOLERANCE IT CAN HOLD
+/-0.5mm typicalcoarsefine+/-1mm+/-0.1mm+/-0.01mm+/-0.005mm
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials

Materials it suits

GradeWhy it suits this
Glass fibre + epoxy/polyesterCheap composite, strong
Carbon fibre + epoxyVery stiff/light
PrepregControlled, autoclave
Design

Design tips

A few general pointers for Composite Layup / Pultrusion. The full, part-specific DFM list is in the dossier.

  • Tight radii / sharp corners. Generous radii for drape.
  • Thick laminate in one cure. Stage cures or de-bulk.
Cost

What it costs

Composite parts (CFRP/GFRP); low volume, high labour and material. Pultrusion is the cheaper continuous cousin.

PER-PART COST vs VOLUME
one-offat volumeVolume per order, low to highCost per part
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$485 to 830 per 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 this process 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
  • The full DFM list and a ready-to-send RFQ draft
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Examples

Parts made by Composite Layup / Pultrusion

91 parts in the finder use Composite Layup / Pultrusion as their primary process. A sample, each with its own guide:

archery bowboat hullbody kitbody panelcarbon fibrecarbon wheelcomposite helmetcomposite partcomposite propellercomposite radomecomposite tubecomposite wingletdrone framef1 chassisfishing rodgolf shafthockey stickhydrogen tankmonocoquenacelle coverpaddlepaddle boardprosthetic limbprosthetic socketrowing oarrowing shellskiski compositesnowboardspar capspoilerstructuresurfboardtennis racketuav fuselagewind bladewing
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FAQ

Frequently asked questions

How is a part 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. The typical route is: Mold prep; Lay plies; Cure; Trim; NDT. High strength-to-weight parts: aerospace structures, wings, hulls and sports frames.
What does Composite Layup / Pultrusion cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $485 to 830 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Composite Layup / Pultrusion hold?
Typically about +/-0.5 mm, tighter with extra finishing operations at higher cost.
What materials suit Composite Layup / Pultrusion?
Common choices are Glass fibre + epoxy/polyester (Cheap composite, strong); Carbon fibre + epoxy (Very stiff/light); Prepreg (Controlled, autoclave).
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