FRP Composite Manufacturing for Automotive, Motorsport and Aerospace
Fibre-reinforced plastic (FRP) parts deliver exceptional strength-to-weight ratio. SkillsProto specialises in carbon fibre and glass fibre prototypes and low-volume parts for the UK automotive, motorsport and aerospace markets — from flat panels to complex shaped components with integrated ribs and inserts.
We use wet lay-up, vacuum bagging and prepreg processes depending on mechanical requirements, cosmetics and lead time.
FRP capabilities overview
| Capability | Specification |
|---|---|
| Processes | Wet lay-up, vacuum bagging, prepreg, RTM |
| Reinforcements | Carbon fibre, glass fibre, aramid (Kevlar) |
| Resins | Epoxy, polyester, vinyl ester |
| Core materials | Foam, honeycomb, balsa |
| Max part size | 1,500 × 1,000 mm typical (larger on request) |
| Typical thickness | 1 mm – 10 mm |
| Surface finish | Gloss, satin, matte; clear coat, paint, gel coat |
| Lead time | 7–15 working days for prototypes |
Carbon fibre vs glass fibre: which do you need?
| Property | Carbon Fibre | Glass Fibre |
|---|---|---|
| Stiffness / strength | Very high | Moderate |
| Weight | Very light | Light |
| Cost | Higher | Lower |
| Impact toughness | Good | Better |
| Best for | Performance, weight-critical parts | Cost-sensitive structural parts |
FRP finishing options
- Clear coat — shows carbon weave, high-gloss or satin.
- Gel coat — durable coloured or white surface for glass fibre.
- Paint / primer — colour matched for body panels and covers.
- Machining after cure — CNC trimming, hole drilling and edge finishing.
Applications of FRP parts
- Motorsport: splitters, diffusers, dashboards, seat backs, engine covers.
- Automotive styling: prototype body panels, mirror caps, interior trim.
- Aerospace: lightweight fairings, ducts, inspection panels.
- Industrial: protective covers, guards, robot shrouds.
- Marine: prototype hull sections, hatches and panels.
FRP design considerations
- Draft angles are not usually needed for FRP moulds.
- Undercuts require split moulds; tell us early so we can design tooling.
- Inserts can be bonded in during lay-up.
- Post-cure machining may be needed for precise hole patterns.
Frequently Asked Questions (FRP Composites)
Q1: Can you make carbon fibre parts with a 3K twill weave finish? A: Yes. We can produce twill, plain weave and unidirectional finishes with clear coat in gloss or satin.
Q2: What is the minimum quantity for carbon fibre parts? A: One-off prototypes are possible but tooling costs spread better across 5–20 pieces.
Q3: How strong are carbon fibre parts compared to aluminium? A: High-modulus carbon fibre can exceed aluminium in stiffness-to-weight and strength-to-weight, but it is more brittle under impact.
Q4: Can you bond metal inserts into FRP parts? A: Yes. Threaded inserts, studs and metal brackets can be bonded or laminated into the part.
Q5: What finish options do you offer for glass fibre? A: Gel coat (white or colour matched), painted, or primed for painting. Textured finishes are also available.
Request an FRP quote
Send your CAD, desired reinforcement and surface finish for a review and quote.
[Request a Quote — FRP Composites]