Composite Engineering & Design Services
From Initial Design to Production-Ready Composite Components
Performance Composites provides composite engineering, CAD design, finite element analysis (FEA), material selection, prototyping, and design for manufacturing (DFM) services. Our engineers work with OEMs to develop new composite components, improve existing designs, and convert metal parts to fiberglass or carbon fiber. With engineering and manufacturing capabilities in California and Nevada, we help customers move from product development to production.
Composite Engineering Services for OEMs
Successful composite manufacturing begins with a design that accounts for material properties, structural requirements, and the intended production process.
Performance Composites supports engineering teams throughout product development, from early concepts to manufacturing preparation.
Our services include:
- Composite Product Design Support
- CAD Modeling and Design Review
- Finite Element Analysis (FEA)
- Structural Design and Analysis
- Design for Manufacturing (DFM)
- Fiberglass and Carbon Fiber Material Selection
- Metal-to-Composite Conversion
- Prototype Development
- Tooling and Fixture Design
- Manufacturing Process Selection
Our engineers and project managers coordinate technical requirements, production planning, and design changes throughout development.
Composite Design Services and CAD Engineering
Composite components require a different design approach than conventional metal or plastic parts. Fiber orientation, laminate thickness, mold geometry, and manufacturing methods influence the finished structure.
Performance Composites works with customer engineering teams to develop practical designs for composite fabrication.
Our engineering team uses CAD data to support:
- Component Geometry Development
- Assembly Fit and Clearance Review
- Mold and Tooling Design
- Mounting Feature Placement
- Design Modifications
- Manufacturing Documentation
CAD models also provide the foundation for CNC-machined tooling and fixtures.
CAD Modeling and Design Development
Computer-aided design allows engineers to establish component geometry, mounting features, and assembly interfaces before manufacturing begins.
Design Reviews and Engineering Support
Early collaboration helps identify manufacturing considerations before tooling is completed. Our engineers review component geometry, material requirements, and production objectives to recommend appropriate composite manufacturing approaches.
Finite Element Analysis and Structural Engineering
Composite structures must be designed around their intended loading conditions and performance requirements. Performance Composites supports engineering and analysis using CAD and FEA to evaluate proposed designs.
Structural Analysis
Finite element analysis helps engineers evaluate how a component may respond to specified loads and boundary conditions. Results can identify areas requiring additional reinforcement or changes in geometry.
Laminate Design Considerations
Unlike metals, fiber-reinforced composites have directional material properties. Structural performance depends on reinforcement orientation, laminate thickness, material selection, and the interaction between individual layers. These factors must be considered when developing a composite structure.
Design Improvements
Engineering analysis can support modifications to existing components when weight, stiffness, or structural performance needs improvement. Changes may involve reinforcement materials, laminate construction, structural supports, or component geometry.
Design for Manufacturing in Composite Engineering
Design for manufacturing connects engineering decisions with practical fabrication requirements. A component that performs well in a digital model must also be suitable for molding, trimming, assembly, and repeat production. Performance Composites evaluates manufacturing considerations during the design process.
Moldability and Tooling Access
Complex shapes must be evaluated for mold release, tooling construction, and manufacturing access. Part geometry can affect tooling cost, fabrication methods, and production efficiency.
Manufacturing Process Selection
Different composite designs require different fabrication methods. Performance Composites offers vacuum infusion, light resin transfer molding (LRTM), prepreg manufacturing, hand layup, and spray layup. Our engineers help determine which process is appropriate for the component’s geometry, material requirements, and production quantities.
Assembly and Hardware Integration
Mounting points, inserts, brackets, and joining methods should be considered before manufacturing. Early planning helps coordinate the composite structure with its intended assembly requirements.
Fiberglass and Carbon Fiber Material Selection
Material selection is a central part of composites engineering because reinforcement and resin properties directly affect component performance. Performance Composites works with fiberglass, carbon fiber, and advanced composite materials.
Fiberglass Composite Design
Fiberglass offers corrosion resistance, electrical insulation, and flexibility for complex molded shapes. It is commonly used for radomes, telecommunications enclosures, transportation components, and industrial structures.
Carbon Fiber Composite Design
Carbon fiber provides high stiffness relative to weight for demanding structural applications. It can be appropriate for aerospace, transportation, and other components where weight and stiffness are important design considerations.
Composite Sandwich Structures
Foam and honeycomb cores can be incorporated between composite skins to increase bending stiffness. Core selection depends on loading conditions, component geometry, and manufacturing requirements.
Metal-to-Composite Conversion
Replacing a metal component with a composite structure involves more than reproducing its original shape. Metals and fiber-reinforced composites respond differently to loading, temperature, and manufacturing conditions. Performance Composites supports customers evaluating conversion opportunities.
Evaluating Existing Components
The engineering process begins with the component’s function, loading requirements, dimensions, and installation conditions.These details help determine whether composite construction is appropriate.
Redesigning for Composite Materials
Composite materials allow reinforcement to be positioned according to structural requirements. This may create opportunities to change wall thickness, incorporate supporting features, or reduce the number of separate components.
Preparing for Manufacturing
A converted design must account for tooling, laminate construction, attachment features, and the selected fabrication process. Prototype development may be used to evaluate the revised component before production.
Composite Prototyping and Temporary Tooling
Prototyping allows manufacturers to evaluate design changes before investing in long-term production tooling. Performance Composites uses 3D design technology, temporary molds, and rapid prototyping methods to support development.
EV Semi Truck Roof Prototype
One featured engineering project involved developing a low-roof component for an electric semi truck. The project used temporary tooling during the development phase, allowing the team to manufacture a composite prototype without first producing a conventional master plug.
Vacuum Infusion with Temporary Molds
Performance Composites demonstrated vacuum infusion using a high-density foam temporary mold. The mold was prepared to maintain vacuum during infusion, providing an alternative tooling approach for the development phase.
Carbon Fiber and Epoxy Construction
The prototype used carbon fiber and epoxy resin to address weight and stiffness requirements. Engineering improvements involved upgrading reinforcement materials and adding a structural beam to strengthen the profile during operation.
Finished Components Ready for Assembly
The developed component received a Class A painted finish and aerospace-grade hardware installation. This project demonstrates how engineering, prototyping, fabrication, and finishing can be coordinated during product development.
Custom Tooling and Fixture Engineering
Tooling and fixtures play an important role in maintaining component geometry and repeatable manufacturing operations.
Performance Composites designs and manufactures tooling for prototype and production applications.
Our capabilities support:
- CNC-Machined Masters
- Composite Production Molds
- Temporary Prototype Molds
- Positional Fixtures
- Cutting Fixtures
- Drilling Fixtures
- Bonding Fixtures
- Preform Patterns
Fixture design is particularly important when components contain mounting hardware, internal supports, or critical assembly features.
Automation and Digital Manufacturing
Performance Composites continues to incorporate digital tools and automated processes into composite manufacturing. These technologies support repeatability and reduce reliance on manual operations for selected production tasks.
3D Printing and Digital Tooling
3D printing can be used to manufacture locating fixtures and other development tools. Digital models also support CNC machining, mold design, and dimensional inspection.
Robotic Sanding
Performance Composites has partnered with a robotics startup to integrate automated sanding into its manufacturing operations. An AI-powered robotic arm is used to sand large composite parts, supporting more consistent processing of suitable surfaces.
Digitization and Inspection
Digital manufacturing tools help connect engineering data with production and quality control. CAD models, 3D scanning, and dimensional measurement provide information that can be used to evaluate manufactured components.
Dimensional Inspection and Quality Control
Engineering requirements must be verified against the completed component.
Performance Composites operates under an ISO 9001:2015 certified quality management system.
Our inspection capabilities include:
- Coordinate Measuring Machine (CMM) Inspection
- Romer Arm Measurement
- 3D Scanning
- CAD-Based Dimensional Verification
- Inspection of Critical Features
- Assembly Fit Verification
Inspection requirements and tolerances are established according to customer drawings and project specifications.
Composite Engineering in California and Nevada
Performance Composites provides American-made engineering and composite manufacturing services from two facilities.
Compton, California
Our 53,000-square-foot Southern California facility supports OEMs throughout Los Angeles County and surrounding aerospace, defense, transportation, and industrial markets.
Reno, Nevada
Our 51,000-square-foot Reno facility provides additional manufacturing capacity for customers in Nevada, Northern California, and other western states. Our teams support customers nationwide, including manufacturers in Arizona, Utah, Oregon, Washington, and Colorado.
Why OEMs Work with Performance Composites
Performance Composites combines engineering support with in-house tooling, fabrication, machining, finishing, and assembly capabilities. With more than 40 years of composite manufacturing experience, we help customers evaluate designs against practical manufacturing requirements.
Our engineering team works directly with customers to address structural requirements, material selection, tooling, and production planning. This coordinated approach supports product development from early design through manufacturing.
Discuss Your Composite Engineering Project
Need composite design services, structural analysis, prototype development, or help converting an existing component to fiberglass or carbon fiber? Performance Composites provides engineering and manufacturing support for custom OEM applications.
Composite Engineering FAQs
Composite engineering involves designing components using fiber-reinforced materials such as fiberglass and carbon fiber. Engineers evaluate structural requirements, laminate construction, component geometry, and manufacturing methods. The goal is to develop a design that meets the intended performance and production requirements.
Yes. Performance Composites supports engineering, design, and analysis using CAD and finite element analysis. These tools help evaluate structural behavior and identify potential design improvements. Analysis requirements are established according to the customer's component specifications and loading conditions.
Yes. Performance Composites supports customers evaluating metal-to-composite conversion. The engineering process considers loading conditions, material properties, attachment requirements, and manufacturing feasibility. A prototype may be developed to evaluate the revised design before production.
Yes. Performance Composites offers prototype development using CAD technology, temporary tooling, and composite fabrication methods. Prototypes can help evaluate component geometry, material construction, and assembly requirements. The company also provides production tooling and manufacturing services when the design is approved.