Curve Works is the first company in the world that offers 3D Composite Kits™, enabling large modular composite builds without the waste from tooling.
Each Kit is composed of sandwich panels with skins on one, or both sides, which can be assembled into a complete structure of unlimited size. In this way, only assembly jigs are required, rather than a large mould to create the part.
We do this using our fully automated reconfigurable mould and unique infrastructure to create all the shapes required for your build.
This approach reduces cost by 40%, lead-time by 50% and material use by >70% compared to manufacturing one-offs in large conventional moulds.
The 3D Composite Kits™ are sandwich panels with single- or double- sided skin, depending on the application.
The structural core is thermoformed according to our own novel process with the skins placed in a secondary process.
The edges of each panel are manufactured according our FlexSkin joint design: single- or multi- step skins. FlexSkin allow structural overlaps to neighbouring panels, even along doubly curved edges.
Curve Works developed a joining method in which the application of the adhesive and the positioning of the panels is uncoupled.
Each panel of the 3D Composite Kit™ is first mounted on the assembly- or subassembly-jig before the seams are infused with the toughened adhesive.
There is no mess and no stress during the assembly process.
The bonding procedure ensures 100% filled joints that are guaranteed vacuum- and water- tight.
