Clients/Case Studies SMAW Launch Tubes - Kevlar epoxy, round tube with exterior molded lugs and cutouts Technical Challenge: to produce two Kevlar tubes via the filament winding process incorporating externally molded features on the outside of the inner tube and the inside of the outer tube. Both tubes also require machined features (slots and holes) to a very tight tolerance in a material that is very difficult to machine cleanly. Solution: creative, high precision tooling has proven to be the key to success on this job. Utilizing sink EDM to create the pockets for the external molds and laser cutting for the high precision slots and holes, truly state of the art processes were required to complete successful program execution. NLOS Launch Tubes - Carbon/glass epoxy, square and octagonal tube set with ultra-precision machined holes and slots (assembly) Technical Challenge: to produce two odd shaped, (one octagonal, one square) Carbon Fiber tubes via the filament winding process incorporating a very thin wall aluminum inner vapor barrier on the ID of one of the tubes. Also, extremely precise holes and slots are required to be post machined into the tubes. Solution: proprietary Industrial Paper Panels - very large (30'), tapered, thin-wall, flat carbon panels Technical Challenge: large, flat thin walled structures made of carbon fiber/epoxy are extremely susceptible to warpage during the curing process. Solution: ultra-precise, balanced lay-up is required every time because any slight inconsistency or imbalance will cause uneven residual stresses resulting in a warped part. Motorcycle (Sport Bike) exhaust pipes - high temperature, high volume, oval shaped carbon tubes Technical Challenge: to produce carbon fiber tubing capable of withstanding 450 degree service temperatures without using an exotic and expensive resin system. Solution: a custom formulated, proprietary "wet-winding" resin system was designed by Composite Solutions to make this project successful. Shock tube for off-road bicycle - highly diverse geometry, multi-process, multi-material, multi-thickness structural tube Technical Challenge: to produce such an odd internal shaped part with the extreme structural requirements imposed at the same time maintaining a cosmetically pleasing exterior. Solution: multiple processes and multiple materials are required to produce this part. Also, very creative tooling has been required to be able to handle multiple processes in the volumes required. Up to 1.000+ units/month. Sonar transducers - thick wall, variable thickness, cut rings Technical Challenge: thick walled structures made of carbon fiber/epoxy are extremely susceptible to de-lamination during the curing process. Solution: proprietary