Composites are engineered materials composed of a matrix material (e.g. polyester or epoxy resins) and a reinforcing material (e.g. glass mat or woven fabric). The process of making a composite is termed Composite Layup, which is derived from the original method of making these materials.

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Hand Layup -

Hand layup is the process where the fibers are positioned manually in the open mold.  A common manufacturing method is to use reinforcements that are pre-impregnated with resin. Such reinforcements are called prepreg. Prepreg is usually stored in cooled areas since activation is most commonly done by heat during composite molding. Prepreg technology is used to lower cost and enhance performance of the completed composites. The resin matrix is applied to the reinforcement, and the wetted fibers are run through nip rollers to produce the prepreg.

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Vacuum and autoclave molding -

In vacuum molding, atmospheric pressure consolidates the material during cure, avoiding the need for a press. A prepreg or fabric laminate is placed on a mold, covered with a flexible membrane and the assembly sealed and evacuated. It provides a low-cost alternative to press molding for large, thin shells. If further consolidation is needed, cure may be done in an autoclave. Autoclaves usually operate at up to 1.5 MPa pressure and are widely used in the aerospace industry, having the advantage over press molding of cheaper tooling for large parts and being ideal for complex structures such as honeycomb core sandwich composites. Indeed, almost all prepreg material used in the aerospace industry is autoclaved.

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STARC employees the most competent and well-trained individuals to perform the complex lay up schedules required in the Aerospace and Satellite industries.