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Zeal 3D Composite Manufacturing Services
Advanced Manufacturing

Advanced Manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, etc.

On Time Project Delivery

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation


Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

Experienced Engineers


Team of expert engineers with more than 15 years of experience.

Composite Manufacturing

Composite manufacturing is the process of creating products using a combination of different materials, such as carbon fibre, fibre sheets, and other composite materials. It involves using composite manufacturing methods designed to optimise the properties of the materials being used. These methods are developed and implemented by experts in composite materials engineering who understand how to create composites that are strong, durable, and highly functional. Some of the products that can be made using composite manufacturing techniques include composite fencing, aerospace components, sporting goods, and many others.

Why Choose Composites for Manufacturing Purposes?

  • Lightweight and Strong : Composites are incredibly strong yet lightweight, making them ideal for use in a wide range of products. This makes them particularly useful in industries like aerospace, where weight is a critical factor.
  • Durability : Composites are highly resistant to corrosion and wear, making them a great choice for products that need to withstand harsh environments.

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  • Versatility : Composites can be tailored to meet the specific needs of a product, allowing manufacturers to create components that are uniquely suited to their application.
  • Cost-Effective : While the upfront costs of composite materials can be higher than traditional materials, the long-term cost savings can be significant due to their durability and low maintenance requirements.
  • Chemical Resistant : Composites possess the remarkable ability to be tailored and engineered to withstand an extensive array of chemicals, rendering them exceptionally well-suited for utilisation in environments where the potential for chemical exposure is a significant consideration. This is particularly important in industries like manufacturing, where harsh chemicals are often used in the production process.
  • Corrosion Resistant : Composites are highly resistant to corrosion, making them ideal for use in products that are exposed to moisture, saltwater, or other corrosive substances. Due to this, they are particularly beneficial in marine applications and the construction of infrastructure, such as bridges and buildings.
  • Heat Resistant : Composites can be engineered to endure high temperatures, which makes them perfect for usage in products that are exposed to extreme heat.

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Composite Manufacturing

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Composite Materials

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Types of Composite Materials

  1. Fibreglass composites : They are made by combining fibreglass (a reinforcing material) with resin or plastic (a matrix material). Fibreglass composites are lightweight, strong, and resistant to corrosion.
  2. Carbon fibre composites: A combination of carbon fibres (a reinforcing material) with resin or plastic (a matrix material). Carbon fibre composites are extremely strong and lightweight, making them ideal for use in aerospace and high-performance sports equipment.
  3. Kevlar composites : They are the mixture of combining Kevlar fibres (a reinforcing material) with resin or plastic (a matrix material). Kevlar composites are highly resistant to impact and are often used in body armour and other protective equipment.
  4. Polyester composites : These composites are made by combining polyester (a polymer matrix material) with a reinforcing material, such as fibreglass. Polyester composites find frequent application in marine contexts due to their exceptional resistance to water and saltwater, making them an excellent choice for such environments.

3D Printing and CNC Machining for Advanced Composite Production

Composite manufacturing has witnessed a significant revolution with the integration of 3D printing and CNC machining technologies. The combination of these advanced processes has opened up new possibilities for creating complex composite structures with exceptional precision and efficiency. 3D printing allows for the fabrication of intricate geometries and the incorporation of reinforcing fibers, while CNC machining ensures the final product meets the desired specifications.

This synergy enables manufacturers to optimise material usage, reduce waste, and enhance overall production speed. By harnessing the power of both 3D printing and CNC machining, composite manufacturing has reached new heights, providing endless opportunities across industries such as aerospace, automotive, and engineering.

CNC for Composite Manufacturing

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Composite Manufacturing Process

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Types of composite manufacturing processes?

Open Mold Processes:

Open mould processes refer to the techniques used to create composites in moulds that are open to the atmosphere. In open mould processes, the mould is typically made of a rigid material, such as metal or fibreglass, and is designed to hold the composite material in the desired shape until it cures. The following are some common open mould processes:

Wet Hand Lay-Up

In this process, a fibre reinforcement material, such as fibreglass or carbon fibre, is placed in a mould by hand. The fibres are then saturated with resin, typically polyester or epoxy, and compacted using a roller or squeegee to remove any air bubbles. The part is then allowed to rest to get the desired material output.
Advantages of Wet Hand Lay-Up:

  • Simple and low-cost process

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  • Suitable for small to large-sized parts
  • Allows for the use of a wide variety of fibre and resin materials
  • Can produce parts with complex shapes

Spray Lay-Up

In this process, fibre-reinforced material and resin are sprayed simultaneously onto the mould using specialised equipment. This process is faster than hand lay-up and allows for the creation of more complex shapes.
Advantages of Spray Lay-Up :

  • Fast process
  • Allows for the creation of parts with complex shapes
  • Uniform fibre/resin distribution
  • Reduced labour compared to hand lay-up

Automated Tape Placement (ATP)

In this process, a machine places pre-impregnated tape or fabric, called "prepreg," onto the mould in a specific pattern to create a composite part. This process is automated and typically used for creating parts with complex shapes.
Advantages of ATP :

  • High precision and repeatability
  • Can produce complex parts with high accuracy
  • Low material waste due to precise placement
  • Low labour costs due to automation

Filament Winding


During this procedure, a continuous fiber reinforcement material, such as fiberglass or carbon fiber, is methodically wound around a rotating mandrel in a precise pattern. Subsequently, the fibers are thoroughly saturated with resin and undergo the curing process. This process is used for creating cylindrical or conical parts such as tubes or pressure vessels.

Advantages of Filament Winding :

  • Can produce cylindrical or conical parts with a high strength-to-weight ratio
  • Can produce parts with uniform fibre distribution
  • It can be automated for high production rates
  • Suitable for high-volume production of parts with consistent dimensions

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CLOSED MOLD PROCESS :

Closed mould processes refer to the techniques used to create composite materials in a mould that is close to the atmosphere. Unlike open mould processes, where the composite is laid up by hand or sprayed into the mould, closed mould processes use a predetermined amount of resin and reinforcement material that is injected or drawn into the mould under vacuum or pressure. Here's an overview of some common closed mould processes:

Autoclave Molding

Autoclave moulding is a high-pressure and high-temperature process that involves the use of an autoclave, which is a specialized pressure vessel. In this process, a prepreg material is placed in a closed mould, which is then placed in an autoclave. The autoclave applies pressure and heat to the mould, causing the resin to cure and bond the fibres together. This process is used to create high-performance composites that require high strength, stiffness, and dimensional stability.
Advantages of Autoclave Molding :

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  • Produces parts with high strength, stiffness, and dimensional accuracy
  • Good surface finish and low void content
  • Suitable for large and complex parts with tight tolerances
  • High repeatability and quality control

Vacuum Infusion

Vacuum infusion is a low-pressure process that involves the use of a vacuum bag to draw resin into a mould. In this process, a dry fibre reinforcement material is placed in a mould, and a vacuum bag is sealed around the mould. The vacuum is then applied to the bag, which draws resin through the reinforcement material and into the mould. This process is used for producing large, complex parts with good mechanical properties.
Advantages of Vacuum Infusion :

  • Produces parts with good mechanical properties and low void content
  • Low material waste due to precise resin placement
  • Suitable for large and complex parts
  • Lower cost than autoclave molding

Vacuum Bag Molding

Vacuum bag moulding is similar to vacuum infusion, but it uses atmospheric pressure instead of a vacuum to compress the material in the mould. In this process, a dry fibre reinforcement material is placed in a mould, and a vacuum bag is sealed around the mould. The air is then removed from the bag, which applies atmospheric pressure to the mould, compressing the reinforcement material and allowing the resin to be drawn into the mould.
Advantages of Vacuum Bag Molding :

  • Lower cost than autoclave molding
  • Suitable for producing small to medium-sized parts
  • Good surface finish and low void content
  • Good mechanical properties

Compression Molding

Compression molding employs a hydraulic press to exert high pressure on a mold, effectively compressing the reinforcement material and resin together in the process. In this process, a dry fibre reinforcement material is placed in a mould, and resin is injected into the mould under pressure. The mould is then heated, causing the resin to cure & bond the fibres together. This process is used to produce parts with complex shapes and good mechanical properties
Advantages of Compression Molding :

  • Produces parts with good mechanical properties and dimensional stability
  • Suitable for producing large parts with complex shapes
  • Low material waste due to precise resin placement
  • High repeatability and quality control

Pultrusion

Pultrusion is a continuous process used to produce composite parts with a constant cross-section, such as rods, tubes, and beams. During this process, reinforcement fibers are drawn through a resin bath and subsequently passed through a heated die. The die serves the dual purpose of shaping and curing the composite material as the fibers progress through it. This process is used to produce parts with a high strength-to-weight ratio and good mechanical properties.
Advantages of Pultrusion :

  • High production rates and continuous manufacturing
  • Good mechanical properties and strength-to-weight ratio
  • Consistent cross-sectional dimensions
  • Low material waste due to continuous process

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Types of Composite Manufacturing

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Composite Manufacturing Industries

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Various Industries that Employ Composite Manufacturing Process

Aerospace: Composite materials are widely used in aerospace manufacturing due to their high strength-to-weight ratio and durability.
Applications:

  • Airframe components, such as wings and fuselages
  • Engine components, such as fan blades and shrouds
  • Radomes and antennas
  • Interiors, such as cabin panels and overhead bins

Appliance: Composite materials are used in various appliances due to their unique properties, including resistance to corrosion and heat.
Applications:

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  • Printed circuit boards
  • Heat exchangers
  • Chemical storage tanks
  • Insulators and electrical housing components

Automotive /Transportation: Composite materials are increasingly used in automotive and transportation industries due to their lightweight and durable properties.
Applications:

  • Body panels
  • Suspension components
  • Driveshafts
  • Hoods and trunks
  • Trailer and truck bed liners

Civil Infrastructure: Used in various civil infrastructure applications because of its longevity, great strength, and resistance to corrosion.
Applications:

  • Reinforcing bars and grids for concrete structures
  • Bridge components, such as decks and girders
  • Pipes and storage tanks for water and sewage systems
  • Anti-corrosive coatings for steel structures

Construction: Employed for manufacturing parts that require strength, durability, and resistance to weathering and corrosion.
Applications:

  • Window and door frames
  • Roofing tiles
  • Siding
  • Facades
  • Structural elements

Electrical: Used for manufacturing parts that require electrical insulation, resistance to heat, and high strength.
Applications:

  • Insulators
  • Connectors
  • Circuit breakers
  • High-voltage equipment
  • Transformers

Marine: Used for manufacturing parts that require high strength, resistance to corrosion, and durability in saltwater environments.
Applications:

  • Boat hulls and decks
  • Propellers
  • Ballast tanks
  • Rudder assemblies

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Why choose Zeal 3D for Composite Manufacturing Services?

Expertise :

Zeal 3D has a team of experienced professionals who are well-versed in composite manufacturing. We use our expertise to create high-quality products that meet the client's requirements.

Advanced Technology :

Zeal 3D uses advanced technology in composite manufacturing to ensure precision and accuracy in the production process. The company invests in state-of-the-art equipment and machinery to ensure that they deliver the best results.

Quality Control :

Zeal 3D adheres to a rigorous quality control process that guarantees every product meets the most stringent standards, leaving no room for compromise. We test each product before it leaves the production facility to ensure that it meets the client's specifications.

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Customization :

Zeal 3D offers customization services for composite manufacturing. We work closely with clients to comprehend their needs and develop products that adhere to their particular specifications.

Competitive Pricing: :

Zeal 3D offers competitive pricing for its composite manufacturing services. Our constant endeavor is to deliver superior quality products at competitive prices, making them an outstanding choice for businesses, regardless of their size or scale of operations.

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Zeal 3D Composite Manufacturing Services

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