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8 FRP composite forming processes in depth

Composite 3D Printing

Composite 3D printing uses additive manufacturing to fabricate continuous- or chopped-fiber reinforced composites directly. Routes include continuous-fiber FDM, chopped-fiber SLS, and others.

PrototypingTooling and fixturesAerospace parts
Compression Molding (SMC/BMC)

Compression molding places SMC (sheet molding compound) or BMC (bulk molding compound) into a heated metal die; pressure forces the charge to fill the cavity and cure. It suits high-volume production of geometrically complex parts.

Automotive partsElectrical componentsManhole covers
Filament Winding

Filament winding deposits resin-impregnated continuous fibers or tapes onto a rotating mandrel along a controlled pattern; the part is then cured and demolded. Winding angle, tension, and resin content are precisely tunable, making it ideal for axisymmetric parts.

Pressure vesselsPipesStorage tanks
Hand Lay-up

Hand lay-up is the most traditional and widely used FRP forming process. Operators place reinforcement (glass fabric/mat) on a mold treated with release agent, then impregnate it with resin using brushes or rollers, building up plies until the design thickness is reached and curing at room or elevated temperature.

Boat hullsStorage tanksCooling towers
Pultrusion

Pultrusion pulls resin-impregnated continuous fibers and mats through a heated die under tension, continuously producing constant-cross-section composite profiles that cure in line.

Cable traysHandrailsWindow/door profiles
Roll Wrapping (Sheet Rolling)

Roll wrapping cuts prepreg sheets at designed fiber angles, rolls them onto a polished steel mandrel, wraps the outside with shrink tape for consolidation pressure, oven-cures, then demolds, sands, and cuts to produce high-quality composite tubes. It is the mainstream process for carbon-fiber tubular goods — fishing rods, bicycle frame tubes, golf shafts, UAV booms, ski poles.

Fishing rodsBicycle frame and seat tubesGolf shafts
Resin Transfer Molding

Resin Transfer Molding (RTM) places dry reinforcement into a closed mold; after clamping, resin is injected under pressure to impregnate the preform and cure. LRTM is the low-pressure variant.

Automotive structural partsRail rolling stockAerospace interiors
Vacuum Infusion (VARTM)

Vacuum infusion (VARTM) lays dry reinforcement and consumables on a single-sided mold sealed under a vacuum bag; atmospheric pressure draws resin through the laminate to impregnate it. It is the dominant process for large parts.

Wind bladesLarge yachtsBridge decks

Process details

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