Composites & Carbon Fibre in Modern Manufacturing: Strength, Precision, and Innovation

In today’s fast-evolving manufacturing landscape, the demand for lightweight, high-performance materials has never been greater. One class of materials leading this charge is composites—engineered combinations of two or more constituent materials with distinctly different physical or chemical properties. When combined, they produce a material with characteristics superior to those of the individual components.

Among the most widely recognised and widely used composite materials is carbon fibre reinforced polymer (CFRP), prized for its incredible strength-to-weight ratio, stiffness, and resistance to fatigue and corrosion. Originally developed for aerospace and motorsport applications, carbon fibre and other advanced composites are now being embraced across multiple industries—including automotive, defence, renewable energy, and even consumer electronics.

As technology advances and the demand for lighter, stronger, and more sustainable components grows, the use of composite materials is rapidly expanding. For manufacturers and OEMs looking to gain a competitive edge, understanding and leveraging the benefits of composites is no longer optional—it’s essential.

Understanding the Two Main Types of Composites: CFRP and GRP

Composite materials come in many forms, but two of the most commonly used in modern manufacturing are Carbon Fibre Reinforced Polymer (CFRP) and Glass Reinforced Plastic (GRP). Each offers unique advantages depending on the application, with differences in strength, cost, weight, and performance under various conditions. Here’s a closer look at both:

• Carbon Fibre Reinforced Polymer (CFRP):
  CFRP is known for its exceptional strength-to-weight ratio, making it the go-to material when performance is critical and weight savings are paramount. Constructed by embedding carbon fibres within a polymer resin matrix—typically epoxy—CFRP delivers rigidity and tensile strength that surpass most metals, all while being significantly lighter.
  • Key uses: CFRP is widely used in aerospace engineering, high-performance automotive components (such as Formula 1 and supercar monocoques), wind turbine blades, sports equipment, and advanced robotics. It is particularly valuable in sectors where precision and efficiency go hand-in-hand with weight constraints. Although more expensive than GRP, CFRP’s superior mechanical properties and fatigue resistance make it the material of choice for high-end or mission-critical applications.
• Glass Reinforced Plastic (GRP):
  GRP, also known as fibreglass, is another popular composite material that consists of glass fibres embedded in a polymer resin. While not as strong or lightweight as CFRP, GRP still offers excellent durability, corrosion resistance, and design flexibility at a fraction of the cost. This makes it an ideal solution for less demanding applications where budget and manufacturability are key considerations.
  • Key uses: GRP is commonly found in construction (roofing panels, cladding, and bridge structures), marine industries (boat hulls and decks), water treatment plants, and general industrial mouldings. It's also used in consumer goods such as bathtubs, surfboards, and storage tanks. GRP’s resistance to moisture and chemicals, combined with ease of forming into complex shapes, gives it a solid foothold across a wide range of sectors.

Below the are pictures of Protec completed projects of both material types:

Composite Manufacturing Methods: From Precision to Volume Production

The versatility of composite materials isn’t just in their properties—it’s also in the many ways they can be manufactured. The method chosen depends on the part’s size, complexity, performance requirements, and production volume. Here are some of the most common and widely used manufacturing processes in the composites industry:

• Pre-Preg (Pre-Impregnated Composite Fabrics):
  Pre-preg is one of the highest-performance composite manufacturing methods. It involves fabrics (usually carbon fibre) that are pre-impregnated with a controlled amount of resin and partially cured. These materials are stored at low temperatures and then laid into moulds by hand or machine before being vacuum-bagged and cured in an autoclave.
  • Best for: Aerospace, motorsport, and high-end automotive components. Pre-preg allows for precise control over fibre orientation, resin content, and part quality, making it ideal for applications demanding consistent strength and finish.
• Resin Infusion (Including Vacuum Infusion and VARTM):
  In this closed-mould process, dry fabric is laid into a mould, sealed under vacuum, and then resin is drawn through the laminate to saturate the fibres. This method produces strong, lightweight parts with excellent surface finish and fibre wet-out.
  • Best for: Large structural components such as boat hulls, wind turbine blades, and automotive panels. Resin infusion is favoured for its ability to produce high-performance parts at moderate cost and lower environmental impact.
• Wet Lay-Up (Hand Lay-Up):
  A traditional and straightforward process where resin is manually applied to reinforcement fibres (such as glass or carbon) in an open mould. Layers are built up by hand and then cured at room temperature or with the aid of heat.
  • Best for: Low-volume or prototype parts, particularly in marine, construction, and industrial sectors. Although less precise than other methods, wet lay is cost-effective, easy to set up, and ideal for large or simple geometries.
• Pultrusion:
  Pultrusion is a continuous manufacturing process used to create constant cross-section composite profiles. Reinforced fibres are pulled through a resin bath and then into a heated die where the shape is formed and cured.
  • Best for: High-volume production of structural profiles like rods, beams, channels, and ladder rails. Pultrusion is common in construction, electrical infrastructure, and lightweight structural applications where uniformity and strength are essential.
• Compression Moulding:
  Involves placing composite material—often in sheet moulding compound (SMC) or bulk moulding compound (BMC) form—into a heated mould, then compressing it under high pressure to cure and form the part.
  • Best for: Medium- to high-volume production of automotive and consumer goods components. Compression moulding is fast and repeatable, with good surface finish and dimensional stability.

Each of these methods offers unique advantages, and choosing the right one can dramatically impact part performance, cost-efficiency, and production scalability. At Protec Group Limited, we understand these nuances and work closely with our customers to deliver composite solutions tailored to their application and manufacturing needs.

Why Choose Composites? Advantages Over Traditional Materials

Composites like CFRP and GRP are rapidly replacing traditional materials such as steel, aluminium, and wood in a wide range of applications—and for good reason. These modern materials offer a powerful combination of properties that give manufacturers greater design freedom, improved performance, and long-term cost savings.

Lightweight with High Strength:

• One of the most compelling advantages of composites is their superior strength-to-weight ratio. Compared to metals, composites can reduce weight by up to 60% without compromising structural integrity. This is crucial in industries like automotive, aerospace, and renewable energy, where reducing mass directly impacts efficiency and performance.

Corrosion and Chemical Resistance:

• Unlike metals, composites do not rust or degrade when exposed to moisture, chemicals, or UV radiation. This makes them ideal for marine, offshore, and chemical processing applications, where durability and longevity are essential.

Design Flexibility:

• Composites can be moulded into complex shapes with minimal assembly, opening up new possibilities for part integration and aesthetic design. Features like curves, tapers, and varying wall thicknesses are easily achievable—helping reduce component count and improve overall product functionality.

Thermal and Electrical Insulation:

• Many composites are non-conductive and exhibit excellent thermal resistance, making them ideal for electrical enclosures, battery housings, and aerospace components where insulation is critical.

Reduced Maintenance and Lifecycle Costs:

• With fewer points of failure, better resistance to environmental factors, and minimal need for coatings or treatments, composite parts typically last longer and require less upkeep than their metal counterparts—saving time and money over the product’s lifecycle.

Challenges and Limitations of Composites

While composites offer a range of benefits, it's important to understand their limitations—especially when considering them for long-term or mission-critical applications.

Recyclability and Environmental Impact:

• One of the main drawbacks of composites, particularly thermoset-based materials like CFRP, is the difficulty in recycling them. Unlike metals, composites cannot be easily melted down and reused. While research into more sustainable alternatives (such as thermoplastic composites and fibre reclamation methods) is advancing, the industry still faces significant challenges in end-of-life management.

Non-Visible Damage (NVD):

• Composites are susceptible to internal or “hidden” damage, such as delamination or micro-cracking, especially after impact. Unlike metals, which visibly deform or dent, composite structures may appear undamaged while harbouring structural weaknesses beneath the surface. This requires advanced inspection techniques—like ultrasound, X-ray, or thermography—for thorough evaluation.

Higher Initial Cost and Processing Time:

• Although composites can lead to cost savings over a product’s lifespan, the up-front costs for materials, tooling, and specialised labour can be higher. Additionally, some composite manufacturing processes are time-intensive and require precise environmental controls, which may not be suitable for all production environments.

Protec Group’s Expertise in Composites

At Protec Group Limited, we’re at the forefront of composite manufacturing, offering a wide range of services—from prototyping to full-scale production. With deep knowledge of advanced materials, cutting-edge fabrication techniques, and rigorous quality control, we help customers harness the full potential of CFRP, GRP, and other composites.

Whether you're developing lightweight automotive components, corrosion-resistant industrial parts, or high-performance structures, our engineering team works with you from concept to completion—ensuring the optimal balance of performance, cost, and manufacturability.

Contact nick.prtak@protecltd.co.uk to discuss you next composite project.