Portfolio

At National Composites, we pride ourselves on applying our advanced technical composite skills into artful solutions. From multiple manufactured items to the custom-designed one-of-a-kind request, National Composites adds the art of perfection into each project.

With our family of multiple locations, molding methods, and over 560,000 square feet of production space, National composites is open to taking on all challenges of all shapes and sizes.

Our career composite specialists team has experience working with customer demands from large parts and small, too highly designed one-of-a-kind artworks.

Waketoon
Complex multi-piece tool lamination and assembly for the marine market

At National Composites, we work in partnership with each of our multiple marine market customers. These dedicated teams collectively complete detailed design reviews and assembly plans to ensure a quality repetitive product regardless of difficulty.

Over 5-years ago, our entree into the composite marketplace was based on our specialized capability to provide marine market hybrid solutions. Today, through our advanced technical-skills and state-of-the-art equipment upgrades, we’ve advanced our marine composite solutions.

Our skilled family of composite crafts-people is proud to say that they have now worked with some of the best-known household names in the boating industry to turn their designers’ dreams into a reality.

Suppose you seek a marine composite manufacturing partner with perfected processes that produce parts from multi-piece open molds. In that case, we are your solution—ensuring a class A Gelcoat surface-look no further than National Composites.

Bonding Example Including Cab
Full FRP (Fibre-reinforced Plastics) cab build and assembly for the construction market

Our experienced team takes care of the details, so our customers meet production schedules and end-use customer deliveries when it’s delivered. At National Composites, we take pride in handling the most complex value-added assembly, designed to meet spec, budget, and design standards.

One example is how our crane cab team open molds the cab out of a multi-piece tool, and then the cab is CNC trimmed, hand finished, assembled, and painted. Additionally, our 360-degree assembly support team installs all the windows, upholstery, electronics, and more to result in a finished cab ready for the production line.

Hospitality Door
Close molded fiberglass door skins

To succeed when serving the hospitality market, one must apply both art and science to meet and exceed customer demands. At National Composites items, food and beverage/hospitality markets require specialty resins to comply with fire and smoke standards as well as eye appealing finishes.

Our team of experienced composite engineers utilizes and sources specialty resins to meet our customer’s needs. Using a closed molding process allows us to produce many different shapes, sizes, textures, and looks.

One such example is this door skins, where our proprietary tooling allows us to create this wood grain look and realistic feel.

2020 Mpi Close Molded Assembly For School Bus
Close molded assembly for school bus

At National Composites, when our customers need to keep the thing on the road, we’re there to support their demands. Through many years of experience working in the specialty vehicle market, producing parts and assemblies for fire trucks, armored vehicles, electric vehicles, we understand success is when the rubber hits the road.

Meeting deadlines, budgets, and safety requirements couldn’t be more critical than when you are producing parts for the school bus assembly. We rely upon RTM (Resin transfer molding) close molded with a primer gel coat when working with this market.

Once that process has been completed, per customer specs, it is hand-trimmed and painted in-house, and inspected for perfection. Then and only then, our assembly team adds all of the lights and mounting brackets. Most importantly, before it ever leaves the door, our team runs the assembly though a quality/safety review, testing the lights and electronics to ensure our customer does not encounter any unexpended issues on their line.

Boom Cab
Fabrication of an Enclosed Boom Cabin for the Aerospace Industry

At National Composites, our integrated services and multiple process capabilities enable us to provide fabrication for complex assemblies resulting in a turn-key cab for our customers. The project highlighted here was designed to keep the operators of enormous boom lifts safe, secure, and protected from the elements. It features a precision-welded aluminum frame with a class-A paint finish, polycarbonate windows, and watertight construction.

Working from customer specifications and a highly coordinated project plan, we designed and built the fixtures, then machined and stamped the parts and installed the clear polycarbonate windows. Dimensional tolerance requirements of +/-.030″, +/-2° angular, required that our welding team display precision control over the joining process when fabricating the cabin housing. More than 71 components, including doors, weather-stripping, wipers, seats, and the interior console, were part of the completed 46.28″ x 42.57″ x 63.21″ assembly.

In-process and post-assembly quality controls, executed following our quality management plan, ensured that the final product was dimensionally accurate, 100% weather-tight, and the electronics fully functional. Multi-disciplined groups of experts working together toward a common goal made this project a success.

Cooling Tower
Fabrication of a Fan Cylinder Access Door Assembly for an Industrial Cooling / HVAC Application

At National Composites, our expertise is frequently called upon to build large fiberglass assemblies with highly specific mechanical and material properties. We manufacture these 165” x 88.5” x 25” fiberglass fan cylinder assemblies for a cooling industry customer. Ultimately used for directing a stream of forced air generated by cylinder fans, each of the units served as a sub-assembly to a much larger build on-site.

Materials of construction included both fire retardant and non-fire retardant gels and resins and specialized reinforcing fabrics. The cylinders feature a foam core designed to eliminate unwanted noise and vibration, adding an enamel coating formulated to withstand outdoor exposure and maintain the desired protective surface quality. 

Once completed, we inspect each component using various precision metrology tools and a 3rd party testing service to verify material and mechanical specifications.

At National Composites, our broad array of expertise enabled us to deliver this quality skillfully and lightweight assemblies that stand up to the stress and abuse of their operating environment.

Open Molding Hood
Fiberglass Lamination & Open Molding of a Hood for the Construction Machinery Industry

At National Composites, our in-depth knowledge of materials and manufacturing has made us a trusted supplier of large parts to the heavy equipment industry. When approached by a customer to fabricate this engine hood, we began the collaboration by conducting a design-for-manufacturability assessment of their part drawing. Our engineers determined that a combination of light fiberglass resin transfer molding and utilizing an open mold process would be ideal for delivering a durable, tight tolerance assembly with a high-quality surface finish and minimized tooling costs.

Building the tooling for the components of this 60″ x 30″ x 25″ fabrication was done in-house and dimensionally inspected by utilizing an advanced technology laser scanning device. We employed multiple fabrication processes to lay-up the parts to precise thicknesses and molded-in steel brackets for added structural stability. A specialty-formulated 2-tone gel coat provided the durable, high-gloss, showpiece type finish. Additional operations included trimming, drilling, and painting the black surfaces. Both in-process and final piece inspections ensured that we met the tight tolerance requirements for material thickness and overall size.

This component’s lightweight durability is field-proven, and we currently manufacture 1000+ units annually for just-in-time delivery to our customers. Contact us today to learn how our team of experts can optimize the production of your equipment components.

Hospitality Door
Close molded fiberglass door skins

To succeed when serving the hospitality market, one must apply both art and science to meet and exceed customer demands. At National Composites items, food and beverage/hospitality markets require specialty resins to comply with fire and smoke standards as well as eye appealing finishes.

Our team of experienced composite engineers utilizes and sources specialty resins to meet our customer’s needs. Using a closed molding process allows us to produce many different shapes, sizes, textures, and looks.

One such example is this door skins, where our proprietary tooling allows us to create this wood grain look and realistic feel.

2020 Mpi Close Molded Assembly For School Bus
Close molded assembly for school bus

At National Composites, when our customers need to keep the thing on the road, we’re there to support their demands. Through many years of experience working in the specialty vehicle market, producing parts and assemblies for fire trucks, armored vehicles, electric vehicles, we understand success is when the rubber hits the road.

Meeting deadlines, budgets, and safety requirements couldn’t be more critical than when you are producing parts for the school bus assembly. We rely upon RTM (Resin transfer molding) close molded with a primer gel coat when working with this market.

Once that process has been completed, per customer specs, it is hand-trimmed and painted in-house, and inspected for perfection. Then and only then, our assembly team adds all of the lights and mounting brackets. Most importantly, before it ever leaves the door, our team runs the assembly though a quality/safety review, testing the lights and electronics to ensure our customer does not encounter any unexpended issues on their line.

Fabrication of an Enclosed Boom Cabin for the Aerospace Industry

At National Composites, our integrated services and multiple process capabilities enable us to provide fabrication for complex assemblies resulting in a turn-key cab for our customers. The project highlighted here was designed to keep the operators of enormous boom lifts safe, secure, and protected from the elements. It features a precision-welded aluminum frame with a class-A paint finish, polycarbonate windows, and watertight construction.

Working from customer specifications and a highly coordinated project plan, we designed and built the fixtures, then machined and stamped the parts and installed the clear polycarbonate windows. Dimensional tolerance requirements of +/-.030″, +/-2° angular, required that our welding team display precision control over the joining process when fabricating the cabin housing. More than 71 components, including doors, weather-stripping, wipers, seats, and the interior console, were part of the completed 46.28″ x 42.57″ x 63.21″ assembly.

In-process and post-assembly quality controls, executed following our quality management plan, ensured that the final product was dimensionally accurate, 100% weather-tight, and the electronics fully functional. Multi-disciplined groups of experts working together toward a common goal made this project a success.

Fabrication of a Fan Cylinder Access Door Assembly for an Industrial Cooling / HVAC Application

At National Composites, our expertise is frequently called upon to build large fiberglass assemblies with highly specific mechanical and material properties. We manufacture these 165” x 88.5” x 25” fiberglass fan cylinder assemblies for a cooling industry customer. Ultimately used for directing a stream of forced air generated by cylinder fans, each of the units served as a sub-assembly to a much larger build on-site.

Materials of construction included both fire retardant and non-fire retardant gels and resins and specialized reinforcing fabrics. The cylinders feature a foam core designed to eliminate unwanted noise and vibration, adding an enamel coating formulated to withstand outdoor exposure and maintain the desired protective surface quality. 

Once completed, we inspect each component using various precision metrology tools and a 3rd party testing service to verify material and mechanical specifications.

At National Composites, our broad array of expertise enabled us to deliver this quality skillfully and lightweight assemblies that stand up to the stress and abuse of their operating environment.

Fiberglass Lamination & Open Molding of a Hood for the Construction Machinery Industry

At National Composites, our in-depth knowledge of materials and manufacturing has made us a trusted supplier of large parts to the heavy equipment industry. When approached by a customer to fabricate this engine hood, we began the collaboration by conducting a design-for-manufacturability assessment of their part drawing. Our engineers determined that a combination of light fiberglass resin transfer molding and utilizing an open mold process would be ideal for delivering a durable, tight tolerance assembly with a high-quality surface finish and minimized tooling costs.

Building the tooling for the components of this 60″ x 30″ x 25″ fabrication was done in-house and dimensionally inspected by utilizing an advanced technology laser scanning device. We employed multiple fabrication processes to lay-up the parts to precise thicknesses and molded-in steel brackets for added structural stability. A specialty-formulated 2-tone gel coat provided the durable, high-gloss, showpiece type finish. Additional operations included trimming, drilling, and painting the black surfaces. Both in-process and final piece inspections ensured that we met the tight tolerance requirements for material thickness and overall size.

This component’s lightweight durability is field-proven, and we currently manufacture 1000+ units annually for just-in-time delivery to our customers. Contact us today to learn how our team of experts can optimize the production of your equipment components.