Our Manufacturing Process For Complete Composite Bodyshells For The Automotive Sector

The automotive industry is undergoing a significant transformation, with composite materials playing a crucial role in the development of lightweight, high-performance vehicles. Complete composite bodyshells are becoming increasingly popular due to their superior strength-to-weight ratio, corrosion resistance, and design flexibility. Below is an in-depth look at the Armstrong Group manufacturing process of these advanced structures.

1. Material Selection and Preparation

The process begins with the selection of suitable composite materials, typically carbon fibre-reinforced polymers (CFRP) or fibreglass-reinforced plastics (FRP). The choice depends on factors such as weight targets, cost constraints and performance requirements.

Once selected, raw materials undergo pre-processing, including cutting, layering and resin impregnation to enhance their mechanical properties. Pre-preg materials (fibre reinforcements pre-impregnated with resin) are used for high-performance applications.

2. Mould Design and Fabrication

To shape the composite bodyshell, precision-engineered moulds are created from aluminum, steel, or high-temperature composite tooling. These moulds dictate the final dimensions and surface finish of the bodyshell components.

On-site CNC machining and 3D printing technologies are utilised to achieve high accuracy in mould production. The mould is then treated with a release agent to prevent adhesion during the curing process.

3. Layup Process

The layup process involves manually or robotically placing fibre layers into the mould in a specific orientation to maximize strength and rigidity. In the case of pre-preg composites, the layers are carefully arranged to ensure uniform resin distribution.

For wet layup techniques, liquid resin is applied manually or via vacuum infusion to saturate the fibres before curing.

4. Curing and Consolidation

Curing is a critical step where the composite material hardens to achieve its final properties. This process  occurs in our autoclave under controlled temperature and pressure conditions.

Autoclave curing uses high heat and pressure to ensure even resin flow and eliminate voids.

Out-of-Autoclave (OoA) curing uses vacuum bagging techniques to cure composites without the need for the high-pressure autoclave, making it more cost-effective.

5. Trimming and Machining

After curing, the composite bodyshell components are trimmed to precise dimensions using CNC routers or laser trimming. This step ensures all edges and surfaces meet the exact specifications for assembly.

6. Surface Finishing and Coating

The bodyshell undergoes sanding, priming, and painting to achieve a high-quality surface finish.

7. Assembly and Integration

Once individual panels and sections are completed, they are bonded or fastened together to form the complete bodyshell. Advanced adhesive bonding techniques, rivets and mechanical fasteners are used to ensure structural integrity.

The bodyshell is then integrated with other vehicle components, including chassis, drivetrain and electrical systems, to form a fully functional vehicle.

8. Quality Control and Testing

Strict quality control measures ensure that each composite bodyshell meets industry standards and safety regulations. Non-destructive testing (NDT) methods, such as ultrasonic testing, X-ray inspection, and visual analysis, detect any defects or inconsistencies.

Structural integrity is validated through crash tests, fatigue analysis and aerodynamic simulations to confirm compliance with automotive safety standards.

The manufacturing process of complete composite bodyshells is a sophisticated blend of material science, precision engineering and innovative manufacturing techniques. With continuous advancements in composite technology, our bodyshells offer an optimal balance of weight reduction, strength and design flexibility, shaping the future of high-performance and sustainable automotive solutions.

Our Manufacturing Process For Composite Interior Centre Consoles And Dashboard Inerts For The Automotive Sector

1. Material Selection and Preparation

The first step in manufacturing composite interior consoles and dashboard inserts is selecting the appropriate materials. Depending on the required strength, flexibility and aesthetic properties, we use:

Carbon fibre-reinforced plastics (CFRP) for premium, high-performance vehicles

Fibreglass composites for cost-effective, durable solutions

Thermoplastic composites for enhanced manufacturability and recyclability

Once selected, the raw materials are prepared by cutting sheets or molding preforms into specific dimensions.

2. Tooling and Mould Design

Moulds and tooling play a critical role in shaping composite components. Precision-engineered moulds are crafted from aluminum or steel, ensuring consistent replication of intricate designs. Advanced CAD software assists in mould design, optimising for efficiency and minimising material waste.

3. Composite Layup and Forming

The composite layup process involves placing layers of material into the mould according to a predetermined pattern. Depending on the manufacturing technique, this can be done manually (hand lay-up) or through automated systems such as:

Resin Transfer Moulding (RTM) – Injecting resin into a closed mould with fibre reinforcements.

Vacuum Infusion – Drawing resin into a mould using a vacuum to ensure uniform distribution.

Compression Moulding – Using heat and pressure to shape thermoplastic composites.

4. Curing and Hardening

The composite material is then cured to solidify its structure. Curing occurs in our autoclave, an oven, or through a heated press, depending on the composite type. The curing process ensures optimal mechanical properties and enhances durability.

5. Trimming and Surface Finishing

Once cured, the component is removed from the mould and trimmed to precise specifications using our state of the art CNC machines or laser cutting machine. Surface finishing techniques such as sanding, painting, hydro-dipping, or applying protective coatings enhance the component’s appearance and durability.

6. Quality Control and Testing

Before being integrated into a vehicle, each component undergoes rigorous quality control checks, including:

• Dimensional accuracy inspection
• Strength and impact resistance testing
• Surface finish and defect analysis

Non-destructive testing (NDT) methods such as ultrasonic or X-ray scanning ensure structural integrity without damaging the part.

7. Assembly and Integration

Finally, the finished composite components are assembled with other interior elements, such as electronic displays, buttons and trim pieces. They are then integrated into the vehicle’s dashboard or centre console, ensuring seamless fitment and functionality.

The manufacturing process for composite interior consoles and dashboard inserts combines precision engineering, advanced materials and innovative production techniques. By leveraging composite technology, we help automotive manufacturers enhance vehicle interiors with lightweight, durable and visually striking components that exceed modern consumer and industry demands.

Our Commitment to Excellence

We partner with automotive manufacturers to develop custom solutions tailored to specific vehicle models. Our team of engineers and designers work closely with clients to ensure every insert meets the highest standards of quality, functionality and aesthetics.

Sustainable & Innovative Solutions

As part of our commitment to sustainability, we incorporate eco-friendly materials and production processes to reduce environmental impact while maintaining superior performance.

Exterior aero kits, including spoilers, diffusers, side skirts and bumpers, play a crucial role in enhancing a vehicle’s aerodynamic performance and aesthetic appeal. In the automotive industry, composite materials such as carbon fibre, fibreglass, and hybrid composites are increasingly used to manufacture these components due to their high strength, lightweight properties and design flexibility. The manufacturing process of exterior composite aero kits is a meticulous combination of advanced material science and precision engineering.

1. Material Selection and Design Requirements

The process begins with selecting the optimal composite materials based on the vehicle’s performance goals, weight reduction targets, and cost considerations.

Common materials we use include:

Carbon fibre-reinforced polymer (CFRP) for high-performance applications

Fibegelass-reinforced plastic (FRP) for cost-effective, durable solutions

Hybrid composites that balance cost, strength, and manufacturability

Design requirements such as downforce, airflow management, and aesthetic integration with the vehicle’s bodywork are defined using computational fluid dynamics (CFD) and 3D CAD modeling.

2. Tooling and Mould Fabrication

Precision moulds are created based on the CAD models. These moulds are typically constructed from high-grade aluminum or steel to ensure longevity and exact replication of complex aerodynamic shapes. For prototypes and low-volume production, composite or epoxy tooling may be used.

3. Layup and Forming Techniques

Composite layup involves arranging fibre fabrics into the mould in a specific orientation to optimise strength and stiffness. Forming techniques we use include:

Prepreg Layup: Layers of pre-impregnated carbon fibre are manually laid into the mould, offering superior consistency.

Wet Layup: Resin is manually applied to dry fabric layers placed in the mould, suitable for lower-cost applications.

Vacuum Bagging and Infusion: Resin is drawn through dry fibres under vacuum pressure, ensuring a uniform, void-free laminate.

4. Curing Process

The formed composite is then cured to harden the material. This step is  performed in our on-site autoclave, applying heat and pressure for high-performance CFRP parts

The curing parameters are carefully controlled to achieve optimal mechanical properties and dimensional stability.

5. Trimming and Finishing

After curing, excess material is trimmed using CNC machining or waterjet cutting to achieve exact tolerances. Finishing processes include:

• Sanding and polishing

• Priming and painting

• Clear coating or UV-protective finishes for carbon fibre

These steps ensure that the final product not only fits precisely but also meets aesthetic standards.

6. Quality Assurance and Testing

Every component undergoes rigorous inspection and testing to meet safety, performance and quality standards. This includes:

• Visual and dimensional inspections

• Structural integrity testing

• Fitment verification on mock vehicle assemblies

Advanced techniques such as 3D scanning and non-destructive testing (NDT) help validate the integrity and consistency of each part.

7. Packaging and Distribution

Finished aero kit components are carefully packaged to prevent damage during transportation. Protective wrapping, custom-fit foam inserts, and reinforced boxes ensure that products arrive in pristine condition, ready for assembly.

The manufacturing process of exterior composite aero kits combines innovative composite technologies with precision craftsmanship. These lightweight, aerodynamic components not only enhance vehicle performance and efficiency but also contribute to striking visual design. As the demand for performance and efficiency grows, composite aero kits continue to be a key focus for forward-thinking automotive manufacturers.

Precision-Crafted Composite Aerodynamics

At Armstrong Group, our manufacturing process is built around one goal: producing high-performance, lightweight and durable aerodynamic components that meet the exacting demands of the automotive world. From concept to final fitment, our method blends cutting-edge technology with hands-on craftsmanship to deliver world-class front splitters and rear diffusers.

1. Design & Engineering

Every component starts with a foundation of aerodynamic engineering and performance-driven design. Using CAD (Computer-Aided Design) software and CFD (Computational Fluid Dynamics) simulations, we create and test virtual models to ensure optimal airflow, downforce and vehicle balance—long before a physical prototype is made.

Processes:

• 3D modeling and simulation
• Vehicle-specific integration
• Custom and universal fitment options

2. Tooling & Mould Creation

Once the design is finalised, we move into precision tooling. We create high-accuracy moulds using CNC-machined patterns or 3D-printed tooling, depending on the complexity and production volume. This ensures repeatable, tight-tolerance components with consistent surface finishes and structural integrity.

Processes:

• CNC-machined master moulds
• Custom jigs and fixtures for complex geometries
• Scalable for low or high-volume production

3. Layup & Lamination

We use a variety of composite materials—including carbon fibre, fibreglass, Kevlar, and hybrid weaves—selected based on strength, weight, and cost targets. Material is hand-laid or pre-preg laminated into the moulds by experienced technicians to control fibre orientation and resin distribution.

Processes:

• Dry carbon (pre-preg) and wet layup options
• Strategic layering for structural strength and flexibility
• Reinforced mounting points and load areas

4. Curing & Consolidation

For maximum performance and durability, our components are cured in temperature- and pressure-controlled environments, typically using autoclave or vacuum bagging processes. This ensures minimal voids, optimal resin content and a perfect bond between layers.

Processes:

• Autoclave and vacuum bagging curing methods
• Controlled temperature and pressure cycles
• High fibre-to-resin ratio for strength and weight savings

5. Trimming & Finishing

After curing, components are de-moulded, trimmed, and post-processed with precision CNC cutting tools or hand-finishing techniques. We inspect every part for structural integrity, surface finish, and dimensional accuracy before moving on to final coating.

Processes:

• CNC trimming or hand-cutting
• Sanding, edge sealing, and polishing
• Optional UV-resistant clear coats, paint, or custom finishes

6. Quality Control & Fitment Testing

Each splitter and diffuser undergoes a rigorous quality control process to ensure it meets both visual and functional standards. We test fitments on actual vehicles or CAD-matched buck models to guarantee perfect alignment with OE mounting points or custom brackets.

Processes:

• Visual and structural inspection
• Dimensional checks and jig-based verification
• Real-world test fitting

7. Packaging & Delivery

Finally, each component is securely packaged to prevent damage during transit. We offer worldwide shipping and partner with logistics providers to ensure safe, timely delivery.

Processes:

• Protective, eco-conscious packaging
• Labeling and part-numbering for inventory management
• Ready for immediate installation or paint prep

Crafted for Performance. Built for Precision.

Whether you’re looking to shave seconds off a lap time or elevate a vehicle’s aesthetic and aerodynamic presence, our manufacturing process ensures you’re getting the best-in-class composite components—every time.