Our Core Manufacturing Competencies by Process Category

1. Open Mold & Liquid Composite Molding (LCM)

Perfect for prototypes, large parts, and complex geometries:

• Hand Lay-up / Wet Lay-up: The foundational process for large marine, wind energy, and architectural components

• Vacuum Bag / Pressure Bag Molding: Enhanced consolidation for aerospace and performance applications

• Resin Transfer Molding (RTM): Our flagship process for medium-volume, complex 3D parts with two-sided finishes

• Vacuum Assisted Resin Infusion (VARI): Advanced large-part manufacturing with excellent fiber-to-resin ratios

2. Compression & High-Pressure Molding

Optimized for high-volume production of consistent, high-strength parts:

• Sheet Molding Compound (SMC) Compression: Automotive body panels, electrical enclosures

• Bulk Molding Compound (BMC) Compression: Electrical components, appliance housings

• Thermoplastic Sheet Stamping: Rapid production of structural automotive components

• ZMC Injection-Compression: High-strength, glass-rich components for demanding applications

3. Continuous Manufacturing Processes

For consistent profiles and panels with exceptional mechanical properties:

• Pultrusion: Constant cross-section profiles (beams, gratings, rails) with unidirectional strength

• Continuous Lamination: Flat and corrugated panels for construction and transportation

• Continuous Pipe Winding: High-pressure pipes and tanks for industrial applications

4. Advanced & Specialized Techniques

For niche applications requiring unique property sets:

• Filament Winding: Pressure vessels, rocket motor casings, drive shafts

• Centrifugal Casting: Uniform wall thickness pipes and poles

• Braiding & Weaving: Complex reinforcement structures for aerospace and medical

• Sandwich Structure Molding: Lightweight, stiff panels for transportation and marine

5. Thermoplastic-Specific Processes

Leveraging the recyclability and reformability of thermoplastic composites:

• Thermoplastic Injection Molding: High-precision, complex parts with fast cycles

• Thermoplastic Extrusion: Continuous profiles and sheet stock

• Thermoplastic Compression Molding: Large-format structural components

• Thermoplastic Tape Lay-up: Aerospace-grade consolidation with weldable interfaces

Material-Process Compatibility: Making the Right Match

Thermoset Composite Processes (Epoxy, Polyester, Vinyl Ester)

• Best For: High-temperature applications, chemical resistance, dimensional stability

• Recommended Processes: Hand lay-up, RTM, compression molding (SMC/BMC), filament winding, autoclave

• Our Material Partnerships: Leading resin suppliers with full formulation support

Thermoplastic Composite Processes (PP, PA, PEEK, PEKK)

• Best For: Recyclability, impact resistance, faster cycle times

• Recommended Processes: Injection molding, thermoplastic stamping, extrusion, tape placement

• Our Material Expertise: Full range from commodity to high-performance engineering thermoplastics

Technology Evolution: Bridging Traditional and Advanced Methods

While traditional processes like hand lay-up remain invaluable for customization and large structures, advanced technologies like automated tape laying and closed-mold infusion are revolutionizing production efficiency and consistency. Our unique capability lies in mastering this full spectrum—applying decades of traditional craftsmanship alongside cutting-edge automation.

Hybrid Approach Example: We frequently combine processes within single projects:

• Filament wound structure + RTM molded fittings for pressure systems

• Compression molded frames + thermoplastic injected details for automotive modules

• Pultruded profiles + secondary bonding/assembly for structural systems

Industry-Specific Process Recommendations

Aerospace & Defense

• Primary Processes: Autoclave, RTM, Automated Tape Laying (ATL), Thermoplastic Welding

• Our Certifications: AS9100, NADCAP (non-destructive testing)

Automotive & Mass Transportation

• Primary Processes: Compression Molding (SMC), Thermoplastic Stamping, RTM, LFT-D

• Our Certifications: IATF 16949, ISO 14001

Electrical & Energy

• Primary Processes: BMC Compression, Pultrusion, Vacuum Casting

• Our Compliance: UL recognition, flame retardant material expertise

Industrial & Consumer

• Primary Processes: Hand Lay-up, Spray-up, Vacuum Infusion, Injection Molding

• Our Strength: Design flexibility, short runs, custom finishing

Success Story: Multi-Technology Implementation

Client: Renewable Energy Systems Integrator
Challenge: Required 8 different composite components for a new wind turbine installation system, with volumes ranging from 50 to 2,000 units annually and varying structural requirements.
Our Technology Solution:

1. Process Analysis: Recommended 5 different processes based on part function and volume:

   • Filament Winding for main torque tubes (high directional strength)

   • RTM for complex mounting brackets (3D complexity, medium volume)

   • Pultrusion for support channels (constant profile, high volume)

   • Vacuum Infusion for large fairing panels (surface quality, low weight)

   • Compression Molding for electrical junction boxes (high volume, flame retardant)

2. Unified Quality System: Single quality management across all processes

3. Integrated Supply Chain: Coordinated material procurement and production scheduling
   Results:

• 22% cost reduction versus single-process outsourcing

• Single technical responsibility for all composite components

• Scalable production framework supporting client growth from pilot to full deployment

Start Your Composite Technology Project

For Engineers, Designers & Procurement Teams:

1. Submit Part Requirements: Share specifications, material preferences, and annual volumes

2. Receive Technology Assessment: Get our expert recommendation on optimal processes

3. Obtain Comparative Analysis: See technical and economic comparisons of suitable methods

Contact Our Technology Advisory Team:
+0086-13511478976 |  info@liberalindustries.com |