Full-scale composite manufacturing from planning to final product

Calian specializes in the design and production of high-precision carbon epoxy antenna structures and other composite products that are rustproof, corrosion-resistant, durable and have a high strength-to-weight ratio.  
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Engineering and technology

Calian’s engineering capabilities embrace the use of industry-leading CAD, FEA and metrology packages, as well as incorporate state-of-the-art methodologies to break new ground in our designs.

Our facility is equipped with <25μm 3D spatial positioning tools and high-precision metrology equipment, allowing us to achieve tight tolerances and validate those tolerances are maintained during production.
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We use high-precision software and lab equipment to verify our designs throughout the product lifecycle to minimize costly redesigns and maximize product performance.

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Composites manufacturing at Calian

Calian’s composites production facility is equipped to manufacture a wide range of composites products that are  lightweight and corrosion resistant. Calian has the ability to mold complex geometries and tolerances all in one manufacturing process.  

Our global customer base has one thing in common: they all work on mission-critical projects. They come to Calian when failure is not an option.


Key capabilities

Material testing laboratory

  • Two-sided composite layup and infusion table for monitoring and analyzing resin flow characteristics through any thickness of composite layup
  • Ultrasonic test machine for void analysis
  • Viscosity, mass and adhesion test equipment
  • Environmental chamber

Metrology and precision

  • FARO and API laser trackers, FARO arm
  • Two 6-axis hexapod positioners
  • Custom-built positioning fixturing that maintains tolerances of <10μm

Jig and tooling manufacturing

  • In-house infused carbon epoxy tooling
  • Rapid prototyping and quantification of existing designs
  • Custom aluminum, steel and carbon composite jigs

CAD/CAE capabilities

  • Industry-leading engineering modeling and simulation package
  • FEA for composites using ply-based or zone-based modeling
  • Static, dynamic, buckling, thermal, modal and adhesive analyses
  • Flat pattern generation
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Workers guide the large assembly installation with a crane, to a structure at a construction site, set against a clear blue sky and trees in the background.
A boat hull under construction in a workshop, with visible structural components and tools nearby.
A factory setting with a large blue metal part on a rolling stand in the foreground and wooden crates and shelves in the background.
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Materials and architectures

We can build to any specifications and design, using your specs or our in-house team of engineers and a variety of materials and architectures.

Resin and adhesive systems

  • Polyester
  • Vinylester
  • Epoxy
  • Methacrylate
  • Urethane
  • Acrylic
  • Silicone


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Reinforcement materials

  • Carbon fibre 
  • Fibreglass 
  • Kevlar 
  • Metallic meshes 
  • Foam/plastic core materials


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Architectures

  • Unidirectional 
  • Woven 
  • Braided 
  • Multi-layer NCS 
  • Veils
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See how Calian delivers durable, high-performance composite solutions from design to final product.

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Calian’s manufacturing capabilities

Calian’s manufacturing processes are incorporated early in the conceptual design phase to ensure manufacturability throughout product development. Our talented team of mechanical engineers, design analysts, technicians and composites fabricators develop products that meet customer design requirements and our end-user expectations.

Vacuum infusion

Maintains remarkable tolerances and ensures strong and lightweight components

Composite jigging

Guarantees repeatable production

Production tooling

Under 50μm RMS with large part tolerances at 100μm RMS and finished assemblies below 170μm RMS

Proprietary in laminate de-icing

Structures with CTE of <7ppm

Custom wet-shim procedure

Developed internally to ensure minimal field re-assembly

<30um surface tolerances

For production of carbon fibre epoxy parts

Production of large parts

Single parts as large as 7m2 and assemblies with surfaces as large as 85m2

Tight tolerances

Can be achieved on individual parts as well as multi-component assemblies

Precision manufacturing

Does not require the use of post-machining

Our manufacturing facility

  • Five-ton overhead and one-ton jib cranes
  • Large paint booth—14’ x 28’
  • Post-cure oven—8’ x 8’ x 20’
  • Product-specific post-of-use manufacturing instructions and part quality documentation and tracking
  • Established list of qualified machine shop partners
  • In-house capability for design and fabrication of customized production jigs

Calian has a reconfigurable manufacturing facility with 34,000 square feet of manufacturing space

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Full product lifecyle support

Calian offers composites-specific engineering, metrology and project planning services, from design right through to full component prototyping with the production of final products and assemblies.

  • Design

    The design stage includes CAD, modelling, requirements development and manufacturing assessments.

  • Analysis

    The analysis phase includes finite element analysis, material testing and requirements validation.

  • Product preparation

    The product preparation phase involves tooling and jig design, product procurement, competency training and all necessary documentation.

  • Prototype

    The prototype phase involves low-cost tooling production or procurement, product validation and manufacturing process verification.

  • Manufacturing

    The manufacturing phase includes material and vendor management, integrated quality system, part production using a broad range of methods and shipping and logistics.

Reach out to our experts to find out how we can help you fulfill your composite manufacturing needs.

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