CSS is your bridge to low cost high quality FRP composite products

Composite Product Development Services

"Convert rough ideas into production worthy composite prototypes ..."

CSS' Composite Product Development engineering services typically focus on carbon fiber (CFRP) and fiberglass or glass fiber (GFRP) reinforced polymer composite applications with complex shapes and challenging fiber architecture:


  • Intricate or Irregular Geometries
  • Non-Uniform Hollow Cavities
  • Radical Cross Section Changes
  • Closed Profiles (e.g., Hoops, Rings)
  • Nested Structures
  • Inserts or Co-Molded Components

Research and IP Development ...

CSS provides or assembles the required fiber reinforced polymer (FRP) composite engineering knowledge and expertise to answer a critical question in most composite endeavors ...

"Are FRP composite materials the best choice for my application?"

Research oriented efforts assess the suitability of composite materials by interrogating the proposed application's intended form, fit, and function.   Uncertainty is mitigated with conceptual trade studies, material performance evaluations, and scale process demonstrations.   CSS' Composite Research oriented programs may include:


  • Material Evaluations and Selection
  • Product Design Studies
  • Producibility Studies
  • Production Cost Approximations
  • Material Experiments
  • Scale Process Demonstrations

Novel Composite Limb


When appropriate CSS can collaborate to refine less established composite product concepts and support the Client's Intellectual Property (IP) development goals, namely securing patent protection.   CSS' IP Development programs can be tailored to include ideation sessions, analysis of competing products, patent searches, and patent application input.

Product and Process Development ...

Most composite product development efforts, such as CSS' Lightweight Multi-Section Composite Davit project, are an amalgam of composite product development and composite process development tasks.   Product development focuses on product design, performance, and appearance while process development addresses material form selection, material layup or placement, tooling design and utilization, and manufacturing methods.

"The best FRP composite solution is a well conceived compromise between composite product performance, product quality (durability), and product manufacturing cost."

Lightweight Multi-Section Composite Davit


CSS utilizes Computer Aided Design (CAD) and basic Finite Element Analyses (FEA) tools to predict carbon fiber and fiberglass composite performance and optimize the composite design for the part geometry ... or optimize the part geometry for maximum composite material performance and/or greater producibility.

Composite prototype fabrication trials may be conducted by CSS, by the Client, or by a prospective composite manufacturer.   The prototype fabrication trials, in addition to validating the manufacturing approach and providing samples for evaluation, allow CSS to optimize the process parameters for a smooth Composite Production transition.

Bladder Inflation Molding Development ...

With more than 20 years of experience designing and manufacturing complex hollow composite structures produced by Bladder Inflation Molding (BIM), CSS helps Clients tackle challenging prepreg and resin infused bladder molded composite product applications.

BIM Composite Stroller Frame Member

Formidable Composite Application Development ...

For composite development efforts requiring outside support CSS maintains an affiliation with the University of Delaware's internationally recognized Center for Composite Materials (CCM) which gives our Clients an opportunity to utilize state-of-the-art composite laboratories and prototype fabrication facilities as well as solicit input from over 100 CCM staff and research professionals, a literal FRP composite think tank.

Warranty & Field Return Problem Resolution ...

CSS also offers composite product design and composite process optimization engineering services for field return and/or warranty problem resolution.

Composite Production Development Case Studies ...


Resin Infused Composite Spool Lightweight Multi-Section Composite Davit BIM Composite Stroller Frame Member

Please Contact Us to learn more about CSS' Composite Engineering capabilities or to discuss your FRP composite program needs.