Tooling Design and Development
Prazastinav Compositech Pvt Limited (PCPL) leads the way with a strategic focus on complex and cutting-edge applications of composite materials. With the passion for problem solving, Prazastinav Compositech Pvt Limited (PCPL) delves into offering the moulding and materials experience to customers wanting to apply the latest materials to a new or existing product.
Prazastinav Compositech Pvt Limited (PCPL) provides composite tooling for all composites processes: Injection, compression, open vacuum bag / lay-up tools, closed RTM with preforms, large thermoset and thermoplastic parts, carbon-fibre lay-up and large bonding assembly applications, advanced composites applications and many more. Tools are the starting point for any composite part manufacturing. The part is only as good as the tool it is made upon. Tools determine the part dimensions, surface finish, tolerances, shape as well as the part appearance, amongst other things.
Prazastinav Compositech Pvt Limited (PCPL) undertakes tooling design, development and manufacturing from the part 3D models with the partner organizations across the globe – paying utmost attention to the moulding strategy, release strategy as well as the manufacturing process compatibility. nDuring the developmental or optimisation stages, we ensure that the tooling’s activities are prioritised and since we specialize in both metallic as well as composite tooling, also ensure that our tools withstand repeated thermal and pressure curing cycles.
Typical types of tools we make are,
- Metal Tools (Stainless Steel or Aluminium and alloys of the same)
- Metal Tools (Invar with composite backing)
- Composite Tools – Glass Fibre Based
- Composite Tools – Carbon Fibre Based
- Composite Tools – Self-Heated High Efficiency
We are also a pioneer in design and manufacturing of self-heated composite tooling.
Prazastinav Compositech Pvt Limited (PCPL) produces composite applications for the Automotive, Aerospace, Marine & Recreation, Heavy Truck, Household, Agriculture, Heavy Engineering, Sports and Leisure, Electrical, Alternative Energy Industries, Defence and Aerospace sectors and many more applications and sectors.
Design and Build Composite Moulds
Mould production for composite part fabrication has played an increasing important role since 1986. Today, we specialize in designing and constructing precision, multi-piece Moulds for demanding applications---particularly highly detailed, complex parts through our partners from across the globe, many from the International Market. Having a team of professionally seasoned tool designers and toolmakers intimately familiar with the materials used in composite structures-such as carbon Fibre, Fibreglass, toughened epoxy, BMI, Polyimide and one-part epoxy systems makes us a resource of choice to the industry. Our knowledge of these materials and their unique processing parameters allows us to produce complex Moulds to exceptionally close tolerances for use in the RTM, Autoclave, Compression Mould , Injection Mould, Pultrusion, LRTM, RIM, VARTM and many other Processes.
Design and Build Composite Tooling
Our ability to conceptualize, design and build the industry's most intricate tooling for composite part production has led to ongoing assignments with the world's principal manufactures of emerging sectors. Engineered Solution's tooling has been used to produce a variety of parts that are used on today's most highly engineered fields. These parts include from Electrical, Automotive to Defence and Aerospace sectors.
Prototyping & Testing
Elevating Performance and Style
Prazastinav Compositech Pvt Limited (PCPL) offers a full range of product development and prototyping services.
From rapid prototyping for form & fit using our state-of-the-art commercial 3D FDM printer, to the complete design and manufacturing of fully functional prototypes using our advanced composite processes.
From rapid prototyping for form & fit using our state-of-the-art commercial 3D FDM printer, to the complete design and manufacturing of fully functional prototypes using our advanced composite processes.
Prazastinav Compositech Pvt Limited (PCPL) has the capability and experience to manufacture using most composite processes and all types of composite materials, including thermo-set, thermoplastic, autoclave & out-of-autoclave. We can help you develop the right manufacturing strategy as well as performing comparative processing studies to determine the best process for production of your product.
These services are complemented with an onsite, fully equipped test and inspection laboratory and certified personnel. We can validate that your product meets all of the required specifications.
Prototyping Capabilities
- Expert knowledge for material selection
- Expert knowledge for process selection
- CAD – quick turn-around tool and part design
- Rapid prototyping (local RP suppliers)
- Composite wet layup / pre-preg
- Surfacing and paint
Why Use Us for Composite Prototyping?
- Building to your drawings, specifications, or ideas
- Determining the key risks and how to avoid them
- Building the first units and determining best processes, achievable tolerances, lowest weight, highest strength, and right stiffness
- Testing the first units to qualify to government or other specifications and demonstrating levels of performance
Testing
The Composite Prototyping Activities offers comprehensive testing services including getting the things executed to the best of the applications at our partnership organizations across the globe, of which many of the partnership organizations have fully equipped, in-house test facility, testing programs, and advanced compliance consulting services
Test Facility (with our partner facilities across the globe):
- Tensile Properties of Plastics
- Tensile Properties of Polymer Matrix Composite Materials
- Tensile Strength (Open Hole) of Polymer Matrix Composite Laminates Testing
- Compressive Properties of Rigid Plastics
- In-Plane Shear Strength of Reinforced Plastics
- Combined Loading Compression (CLC)
- Flexural Properties of Unreinforced and Reinforced Plastics
- Core Shear Properties of Sandwich Constructions
- Long Beam Flexure
- Compression After Impact
- Gel Time
- Tack
- Volatile Content
- Resin Flow
- Resin Content and Fibre Areal Weight
- Environmental Simulation Test Services, including; Shock, Vibration, Temperature, Temperature/Humidity, Salt Fog, Sand and Dust and many more
Compliance Consulting Services:
Prazastinav Compositech Pvt Limited (PCPL) also provides compliance consulting services. Thoroughly experienced experts are available to assist manufacturers in identifying the specific compliance testing requirements necessary to address their customer’s requirements.
Testing Programs: Consulting will be available to assist in the creation of testing programs that will allow for the broadest acceptance of products into multiple marketplaces. Testing related documentation services, including the generation of test plans and procedures, are also available.
Testing Programs: Consulting will be available to assist in the creation of testing programs that will allow for the broadest acceptance of products into multiple marketplaces. Testing related documentation services, including the generation of test plans and procedures, are also available.
Process Definition, Process Designing and Development
The 'What' comes from our customers - we take care of the 'How'. When it comes to engineering, weight and functionality are key parameters that are just as important as costs and deadlines. The objective is to always provide the best turnkey solution for efficient right first time production. Customers can rely on Prazastinav Compositech Pvt Limited (PCPL) achieving this goal because we reduce development times by means of concurrent engineering and take customer orientation and proximity quite literally. Manufacturing Process Design is the most critical aspect towards ensuring consistency and repeatability in the parts manufactured. Ideally Product Design must consider Manufacturability aspects. We develop, optimize and transfer Composite Manufacturing Processes for our clients who, themselves, are leaders in the Advanced Composites sector.
Process development and optimization can either be initiated for a brand new project or for an established product (especially when the existing process is yielding unpredictable results).
Prazastinav Compositech Pvt Limited (PCPL) takes up Manufacturing Process Development right from the Mould Strategy onwards up to Final Quality Assurance Plans – integrating everything under its Process Framework.
Typically we end up with providing clients with specific measurable results like,
• Reduction in Rejection
• Improve Consistency & Repeatability
• Assure Interchangeability
• Improve tolerances & meet stringent specifications
• Improve specifications of product (like void content, Fibre volume etc.
• Any other specific outcome desired by the client
Many times, our final client for Process Development & Optimization are existing Composite Manufacturers themselves. We respect Customer Privacy & honour the Non-Disclosure Agreements with all our clients – ultimately, the relationships we have built are based on Trust.
• Reduction in Rejection
• Improve Consistency & Repeatability
• Assure Interchangeability
• Improve tolerances & meet stringent specifications
• Improve specifications of product (like void content, Fibre volume etc.
• Any other specific outcome desired by the client
Many times, our final client for Process Development & Optimization are existing Composite Manufacturers themselves. We respect Customer Privacy & honour the Non-Disclosure Agreements with all our clients – ultimately, the relationships we have built are based on Trust.
System Integration
Our experts have expertise in composite production and in efficient manufacturing. This combined expertise enables Prazastinav Compositech Pvt Limited (PCPL) to provide you the most appropriate system integration solutions for your production facilities. By applying the latest technologies, Prazastinav Compositech Pvt Limited (PCPL) creates solutions that give you more reliability, savings, safety, efficiency and therefore quick return on your investment. Based on our extensive experience and cooperation with many partners and suppliers, we can offer our customers the comprehensive solutions they can expect from us.
Product Data Management and Technical Documentation
Whilst the manufacturing is being done, our design team put their mind to developing the other outputs for the client, they will produce detailed user manuals, maintenance manuals, specification sheets, general arrangement engineering drawings and other key documents that the client will need to accompany their product.
Prazastinav Compositech Pvt Limited (PCPL) Company can provide guidance and material data for customers doing their own CAE analysis. We have a proprietary company database and can do in-house testing and curve-fitting for both standard and custom materials. Your custom materials data will be processed with Prazastinav Compositech Pvt Limited (PCPL) ’s strict confidentiality procedures. If you do not find the Prazastinav Compositech Pvt Limited (PCPL) material you’re looking for in your injection Moulding software database, contact us! We have over 400 materials characterized for flow simulation and if your material is not already characterized, we can help you understand the details of how the material will behave and the level of testing required to accurately predict its behaviour during Moulding. Prazastinav Compositech Pvt Limited (PCPL) understands that the better the predictions are from the start, the better the overall project outcomes will be. With that being said, even if a reasonable material model doesn’t exist, we’ll test it for you!
Prazastinav Compositech Pvt Limited (PCPL) Company can provide guidance and material data for customers doing their own CAE analysis. We have a proprietary company database and can do in-house testing and curve-fitting for both standard and custom materials. Your custom materials data will be processed with Prazastinav Compositech Pvt Limited (PCPL) ’s strict confidentiality procedures. If you do not find the Prazastinav Compositech Pvt Limited (PCPL) material you’re looking for in your injection Moulding software database, contact us! We have over 400 materials characterized for flow simulation and if your material is not already characterized, we can help you understand the details of how the material will behave and the level of testing required to accurately predict its behaviour during Moulding. Prazastinav Compositech Pvt Limited (PCPL) understands that the better the predictions are from the start, the better the overall project outcomes will be. With that being said, even if a reasonable material model doesn’t exist, we’ll test it for you!
Engineering Data Analytics (WIP)
A Prazastinav Compositech Pvt Limited (PCPL) platform focused on solutions
Prazastinav Compositech Pvt Limited (PCPL)’s Data Analytics solution platform is a specialized set of solutions that combines state of the art Engineering Data Analytics and management approaches, intuitive visualization and efficient investigation methodologies to allow for a fast discovery of the unknown in large high-dimensional datasets.
Prazastinav Compositech Pvt Limited (PCPL) brings its long-standing innovative capability and its expertise in designing solutions tailored for professionals who need to solve difficult high-value problems.
Prazastinav Compositech Pvt Limited (PCPL) also helps its customers face the Big Data challenges induced by the ever-increasing size and complexity of simulation data. Considering the total cost of ownership of such simulation data, and all of the efforts needed to produce high-quality simulations, the Data Analytics solutions brought by Prazastinav Compositech Pvt Limited (PCPL) improve the ROI and leverage the benefits of critical knowledge captured by engineers.
Prazastinav Compositech Pvt Limited (PCPL)’s Data Analytics solution platform is a specialized set of solutions that combines state of the art Engineering Data Analytics and management approaches, intuitive visualization and efficient investigation methodologies to allow for a fast discovery of the unknown in large high-dimensional datasets.
Prazastinav Compositech Pvt Limited (PCPL) brings its long-standing innovative capability and its expertise in designing solutions tailored for professionals who need to solve difficult high-value problems.
Prazastinav Compositech Pvt Limited (PCPL) also helps its customers face the Big Data challenges induced by the ever-increasing size and complexity of simulation data. Considering the total cost of ownership of such simulation data, and all of the efforts needed to produce high-quality simulations, the Data Analytics solutions brought by Prazastinav Compositech Pvt Limited (PCPL) improve the ROI and leverage the benefits of critical knowledge captured by engineers.
Manufacturing Engineering (including cost effective manufacturing technology)
Using our experience, we can select the right process depending on your product, the series and cost. Prazastinav Compositech Pvt Limited (PCPL) provides manufacturing engineering solutions that enable clients to perform virtual validation and optimization of manufacturing systems prior to the actual production, helping them reduce product realization cycle time and improve productivity.
Our Technical and Composites Expert Group have a unique combination of practical and theoretical experience from various industries and sectors to ensure that the composites manufacturing solutions are valuable from both a design and a manufacturing perspective. Together with the clients, Prazastinav Compositech Pvt Limited (PCPL) decides on the best combination of technology, machineries and equipment’s, system and process according to the need of the clients.
We support composite component manufacturers to optimize production performance for a wide range of composite products and processes
• Developing the most cost effective and efficient solutions that satisfy design to cost and design for manufacture
• Specifying material requirements, define suitable methods of manufacture and identify and implement tooling and equipment
• Developing processes to a production steady state standard that meets specification and design intent
• Support Production and Quality Assurance in resolving production problems and non-conformances
• Utilize Lean Principles to improve the product, process flow, build cycle and waste reduction
• Offer complete process coverage, from design and analysis to production
• Ensure manufacturability by integrating all requirements early in the design phase
• Perform structural and technical calculations
• Help you select the optimal core material and finishing
• Help you design the optimal kit
• Reduce the time and cost of production
Our Technical and Composites Expert Group have a unique combination of practical and theoretical experience from various industries and sectors to ensure that the composites manufacturing solutions are valuable from both a design and a manufacturing perspective. Together with the clients, Prazastinav Compositech Pvt Limited (PCPL) decides on the best combination of technology, machineries and equipment’s, system and process according to the need of the clients.
We support composite component manufacturers to optimize production performance for a wide range of composite products and processes
• Developing the most cost effective and efficient solutions that satisfy design to cost and design for manufacture
• Specifying material requirements, define suitable methods of manufacture and identify and implement tooling and equipment
• Developing processes to a production steady state standard that meets specification and design intent
• Support Production and Quality Assurance in resolving production problems and non-conformances
• Utilize Lean Principles to improve the product, process flow, build cycle and waste reduction
• Offer complete process coverage, from design and analysis to production
• Ensure manufacturability by integrating all requirements early in the design phase
• Perform structural and technical calculations
• Help you select the optimal core material and finishing
• Help you design the optimal kit
• Reduce the time and cost of production
Test methodology for Composites Parts and Products
At Prazastinav Compositech Pvt Limited (PCPL), we can determine the properties of a variety of polymers and polymer composite materials, providing you with reliable data. This data is supported by expert analysis and interpretation, allowing you to properly evaluate the performance of your materials.Our experts have the ability to produce accurate and fast composite product and materials test results for composites, and related materials. Prazastinav Compositech Pvt Limited (PCPL) defines the able tests for the composites parts and products for end use, avoiding future failures. Many products cannot be tested in a manner equivalent to their end use. Although it is possible to simulate operation by applying temperature and pressure changes, other conditions, such as bending and load combinations, cannot be reasonably simulated in a test situation. Through a combination of analytical modeling and non-destructive and destructive laboratory tests, Prazastinav Compositech Pvt Limited (PCPL) provides meaningful evaluations that are appropriate for the end use of the product and also defines the test methodologies to match to the exact product requirements.
Often, load conditions specified in composites testing standards do not relate to the actual end use of the product. Prazastinav Compositech Pvt Limited (PCPL) integrates a variety of analytical and testing techniques, such as tensile strength testing, ignition loss testing (burn test), and hydro and burst testing, combining the strengths of each to gain the highest confidence in the adequacy of the product for the intended service.
Prazastinav Compositech Pvt Limited (PCPL) support customers across the global aerospace, automotive, building, chemical, consumer, energy, manufacturing, medical, and materials industries with our world-leading facilities, experts, and solutions. Composite materials tested include thermoset and thermoplastic composites, laminates, Fibre reinforced composites, core materials, resins, films and adhesives.
Prazastinav Compositech Pvt Limited (PCPL):
• Reviews the product/equipment process and design requirements, including fabrication methods, corrosion requirements, and strength requirements.
• Determines expected laminate physical properties through laminate theory analysis after reviewing fabrication methods and raw materials.
• Determines the expected mode of failure for the equipment through engineering analysis, including first sign of failure and ultimate structural failure.
• Test the whole product or the critical parts of the equipment to determine capabilities. Test aids are employed as required to improve the analytical results, including strain gauging and Acoustic Emission testing.
• Along with the Test Laboratories who are an integral part of Prazastinav Compositech Pvt Limited (PCPL), we test the products for evaluating the exact product requirements, that would ensure matching with the concept and the theory.
• Report findings — including comparison of actual test results with theoretical analysis — for product analysis, evaluation, and confirmation.
Often, load conditions specified in composites testing standards do not relate to the actual end use of the product. Prazastinav Compositech Pvt Limited (PCPL) integrates a variety of analytical and testing techniques, such as tensile strength testing, ignition loss testing (burn test), and hydro and burst testing, combining the strengths of each to gain the highest confidence in the adequacy of the product for the intended service.
Prazastinav Compositech Pvt Limited (PCPL) support customers across the global aerospace, automotive, building, chemical, consumer, energy, manufacturing, medical, and materials industries with our world-leading facilities, experts, and solutions. Composite materials tested include thermoset and thermoplastic composites, laminates, Fibre reinforced composites, core materials, resins, films and adhesives.
Prazastinav Compositech Pvt Limited (PCPL):
• Reviews the product/equipment process and design requirements, including fabrication methods, corrosion requirements, and strength requirements.
• Determines expected laminate physical properties through laminate theory analysis after reviewing fabrication methods and raw materials.
• Determines the expected mode of failure for the equipment through engineering analysis, including first sign of failure and ultimate structural failure.
• Test the whole product or the critical parts of the equipment to determine capabilities. Test aids are employed as required to improve the analytical results, including strain gauging and Acoustic Emission testing.
• Along with the Test Laboratories who are an integral part of Prazastinav Compositech Pvt Limited (PCPL), we test the products for evaluating the exact product requirements, that would ensure matching with the concept and the theory.
• Report findings — including comparison of actual test results with theoretical analysis — for product analysis, evaluation, and confirmation.