We provide full concept-thru-delivery product development, or any of the steps along the way.
Our strength is in applications and products where world-beating performance matters
(and conversely, if you’re looking for mass production of low-grade goods, we’re not likely your candidate).
Starting with a product concept, the process includes:
Any or all of these processes can be applied to your project, and/or worked in collaboration with your team.
Tooling & Molds
Tooling and molds are developed and built in-house using a maximally digital process.
This minimizes the process distance between your finished product and the ideal 3D computer model.
Leapfrogging the traditional methods involving fabricating master parts, then makig frames & molds off of the masters, etc., we utilize advanced tooling materials and 3D CAD, CAM and CNC (computer aided design, computer aided manufacturing, computer numeric control) machining to cut the molds directly from the 3D models.
Structural & Syntactic Foam & Cores
Structural foams are cellular engineering-grade plastics with high strength, high toughness, and light weight. They superficially resemble wood, but with much higher strength and durability, no grain, and a wide range of available densities.
Syntactic foams incorporate micro-balloons which create a material that is buoyant yet able to withstand the compressive forces in the deepest ocean trenches.
Carbon fiber structures often include structural foam core sections to multiply the stiffness of a structure with a trivial weight increase.
In underwater vehicle applications, structural or syntactic foams can be used alone or with composite shells to form the buoyant and hydrodynamic components.
The exceptional properties of these materials come with significant fabricating and machining challenges – we have the extensive experience required to reliably and effectively design and manufacture complex components from these materials.
Process Technology Capabilities
Prime Composites LLC
98 Franklin Street Ext.
Derry, NH 03038