Research & Development
In it with the innovators
We thrive at the leading edge of composite research and development, utilising new technologies and techniques to push our clients further.
Our team gets up in the morning to hear clients say things like "Can this actually be done?" or "We might be crazy, but could we...".
From developing the application of composite nanotechnology to finding a way to 3D print and produce the largest carbon sculpture ever made in New Zealand, if it pushes the boundaries, we're all in.
Specialist Capabilities
The Process
If you know that you need a product or component to meet certain criteria but you're still working out the design and want to test and learn as you go, let's work in parallel.
Here's how.
"We'd never attempted anything like this before."
Emirates Team New Zealand
An alignment of values, coupled with fast-paced prototyping meant a perfect partnership.
Te Ahi Tupua
Stacey Gordine and his team scoured the globe for someone who could build their 12-meter-high structure, to no avail. Then Kilwell Fibrelab presented a solution, right on their doorstep.
LTA Research
When LTA research needed a production partner for their 21st-century Airship, they tested the world's best. And they chose Kilwell Fibrelab.
Hardy Rifle Engineering
Hardy Rifle Engineering set out with a clear goal; produce a world-leading precision rifle that combines incredible accuracy and usability with showstopping design.
Composite materials are made by combining fibres, such as carbon or glass, with a resin system to create a material with specific performance characteristics. In product development, they are used where advantages such as reduced weight, increased strength, or tailored performance are required. Their properties can be adjusted to suit different applications.
Composites offer a high strength-to-weight ratio, corrosion resistance, and the ability to be engineered for specific performance requirements. This makes them suitable for applications where traditional materials may not provide the desired balance of performance, weight, or durability.
Yes, composite materials can be designed to achieve specific properties by adjusting factors such as fibre type, orientation, and resin system. This allows characteristics like stiffness, strength, and flexibility to be tailored to suit the needs of a particular application.
Composite materials are typically tested through a combination of material testing and application-specific evaluation.
This can include testing for strength, stiffness, fatigue behaviour, and environmental performance, depending on how the material will be used. Testing helps confirm that the design performs as intended before further development or production.
Composites generally perform well under repeated loading when properly designed.
They can distribute stresses through the fibre structure, which helps maintain performance over time. Their behaviour depends on the material system and design, but they are often used in applications where long-term durability is important.
Developing a composite prototype typically involves defining performance requirements, selecting materials, designing the structure, and producing a sample component. Prototypes are then tested and refined to improve performance and ensure the design meets the intended application.
Composite manufacturing processes can be highly controlled, allowing for consistent and repeatable results. Once a design and process are established, components can be produced with predictable performance and dimensional accuracy, depending on the manufacturing method used.
Composites are often considered when weight reduction, corrosion resistance, or tailored performance are important factors. They can be a good option when traditional materials such as steel or aluminium do not meet the required performance or environmental conditions.
