Development for all applications
Definition of Objectives & Specification
Design & Simulation
Choice of materialsWhat we can do
Well thought out from the very beginning
Requirements Analysis
Together, we define objectives, operating conditions and interfaces – as a clear basis for the development process.
Materials & Concept
Material systems, processes and component designs are specifically selected on the basis of temperature, load and geometry.
Design & Simulation
Using CAD and FEM, we develop robust structures, evaluate different options and optimise performance and weight.
Prototyping & Testing
Prototypes are manufactured and tested in the laboratory – including mechanical tests and thermal stress tests.
Choice of materials
Precision materials analysis
We assess operating conditions, temperatures and environmental factors, and select material systems that perform reliably. In doing so, we take into account fibre types, resins, layer configurations and processes – all tailored to the intended function and required performance.
Manufacturing
Structures designed to be safe
Using CAD, FEM and laminate design, we develop composite components that are precisely tailored to their function and the loads they will be subjected to.
Digital analyses enable us to compare different variants, optimise geometries and achieve reproducible structural results.
Testing
Components reliably tested
We manufacture prototypes in-house and test them under real-world conditions – mechanically, thermally and functionally. The results are incorporated directly into the optimisation process, documentation and approval for series production.
All done in-house
In-house production right through to the
finished component
Mechanical reworking
Precise CNC finishing
and clean contours for accurate fits and components ready for assembly.
Bonding of fittings
Structural bonding processes for creating strong bonds between attachments, inserts and functional components.
Assembly
Inserts, bushings and ancillary parts are positioned with precision and assembled in a repeatable manner.
Surface finish
Painted, coated, textured or antistatic – surfaces tailored to their function and application.
Frequently asked questions about development.
The key answers at a glance. And if you have any further questions, we’re here to help in person.
To get the project off the ground, we need, above all, a shared understanding of what the component is intended to achieve. It is helpful, for example, to provide details on the application, installation space, loads, temperature range, quantity, target weight, interfaces or existing reference components.
If complete data, drawings or specifications are not yet available, that is not a problem. We provide particular support during this early phase and, if required, can oversee the entire development process — from the initial definition of objectives right through to a production-ready design.
what we can do
Our core competencies
Two worlds. One material. Fibre composites.
Fibre-reinforced thermal protection systems
Composite Impulse develops project-specific fibre-reinforced composite thermal protection systems for operating temperatures of up to 1,000 °C. This results in rapidly available prototypes and production-ready solutions — built on over 30 years’ experience in the top tiers of motorsport and applied to the aerospace and industrial sectors.
Fibre-reinforced composite structures
Composite Impulse develops, validates and manufactures fibre-reinforced composite components, sub-assemblies and complete systems in-house. This enables prototypes to be produced within a few weeks and series production solutions to be delivered with reduced investment risk — underpinned by certified processes in accordance with EN 9100, ISO 9001 and EASA Part 21G.