CSS is your bridge to low cost high quality FRP composite products

Composite Product Development Services

"Convert rough ideas into production worthy composite prototypes ..."

CSS' Composite Product Development engineering services typically focus on carbon fiber (CFRP) and fiberglass (GFRP) reinforced polymer composite applications with complex shapes and challenging fiber architecture:


  • Intricate or Irregular Geometries
  • Non-Uniform Hollow Cavities
  • Radical Cross Section Changes
  • Closed Profiles (e.g., Hoops, Rings)
  • Nested Structures
  • Inserts or Co-Molded Components

Research and IP Development ...

"Are FRP composite materials the best choice for my application?"

Early development and research intensive efforts assess suitability by interrogating the FRP composite material form, fit, and function within the proposed application.   Uncertainty is mitigated with conceptual trade studies, material performance evaluations, and scale process demonstrations.   CSS' Composite Research oriented programs often include:


  • Material Evaluations and Selection
  • Product Design Studies
  • Producibility Studies
  • Production Cost Approximations
  • Material Experiments
  • Manufacturing Demonstrations

Novel Composite Limb


CSS also collaborates to refine less established composite product concepts and supports the Client's Intellectual Property (IP) development goals, namely securing patent protection.   IP Development programs can be tailored to include ideation sessions, analysis of competing products, patent searches, and patent application input.

Product and Process Development ...

Most composite product development efforts, such as CSS' Lightweight Multi-Section Composite Davit project, are an amalgam of composite product development and composite process development tasks.   Product development focuses on product design, performance, and appearance while process development addresses material form selection, material layup or placement, tooling design and utilization, and manufacturing methods.

"The best FRP composite solution is often a well conceived compromise between composite product performance, product quality, and product manufacturing cost."

Lightweight Multi-Section Composite Davit


CSS utilizes Computer Aided Design (CAD) and basic Finite Element Analyses (FEA) tools to predict the composite structure's performance and optimize the composite design for the specified geometry ... or optimize part geometry for greater producibility and/or composite performance.

Composite prototype fabrication trials may be conducted by CSS, by the Client, or by a prospective composite manufacturer.   Prototype fabrication trials, in addition to validating the manufacturing approach and providing samples for evaluation, allow CSS to optimize the process parameters for a smooth Composite Production transition.

Bladder Inflation Molding Development ...

With more than 30 years of experience designing and manufacturing complex hollow composite structures produced by Bladder Inflation Molding (BIM), CSS helps Clients tackle simple to complex prepreg and resin infused bladder molded composite product applications.   BIM services include custom bladder development, BIM air fitting and tooling design, and BIM tailored product design and process development support.

BIM Composite Stroller Frame Member

Laboratory Intensive Application Development ...

CSS maintains an affiliation with the University of Delaware's internationally recognized Center for Composite Materials (CCM) to offer Clients access to state-of-the-art composite laboratories and prototype fabrication facilities as well as solicit input from over 100 CCM staff and research professionals, a literal FRP composite think tank.

Composite Product Development Case Studies ...


Resin Infused Composite Spool Lightweight Multi-Section Composite Davit BIM Composite Stroller Frame Member

Please Contact Us to discuss your FRP composite program needs or learn more about CSS' Composite Engineering capabilities.