Flexibility and driving for the most efficient solution

My passion for composites began in 2007 with the construction of sailplane prototypes while graduating as an aerospace engineer in Germany. This was followed by my work on the engineering and production of Stemme high-performance composite planes for surveillance and recreation. The need for efficient designs and production methods became clear when I started my venture, LeichtLast, in Germany, where we designed and produced cutting-edge carbon fiber cargo bikes. “Rocket-science” techniques weren’t suitable for a product where price is key. I’m not the type of salesperson who enjoys persuading others to buy something. I prefer to get things done, improve each time, and constantly seek new ways to increase efficiency. This is why I sold the cargo bike business after moving to the U.S. and dedicated myself solely to composite production and engineering.

Our services

Advanced Composite Parts Production

Discover the future of manufacturing with our state-of-the-art advanced composite parts production services, ranging from prototypes to 1k batches. Specializing in high efficiency, we deliver precision-engineered components tailored to meet specifications across various industries.

For small part quantities and specific surface requirements, hand layup is typically our method of choice. For larger parts and superior surface quality, especially for clear-coated carbon components, infusion with film bagging is usually the best approach.

For small series production, it becomes more efficient to invest in better tooling and switch from a bagged process to closed molds. For larger parts, we prefer the light RTM process, while smaller parts are often easier to produce using the conventional RTM process.

Aeronautic Engineering and Airframe Repairs

We have extensive experience in aircraft certification, modification, and repairs.

We perform aircraft repairs in accordance with German and European certification standards, using exclusively aircraft-approved materials sourced from Europe. While we do not hold an FAA certificate for airframe repairs, we adhere to the highest aeronautical standards for every repair, regardless of your aircraft’s certification. If certification of the repair is required, we collaborate with the A&P responsible for your aircraft to ensure all paperwork is properly completed.

Depending on the size of the part that needs repair, we can perform the work either in our facility or at your hangar to simplify logistics.

Composite Tooling

Do you have your own composite capabilities? We can build the right tools and jigs for your product. If you already have the pattern or need an existing part to be made out of composites, we can create the molds from there. If you are starting a part from scratch, we can build a 3D-printed or milled pattern for you.

With our experience in producing aircraft and cargo bikes, we can also provide tools that are suitable for higher volumes and integrate them into your existing production environment.

Reverse Engineering

In many cases, composite materials are used to improve the performance and appearance of existing parts. In these cases, there are many different reverse engineering approaches to consider.

We have a variety of tools on hand to help you with your project, from conventional mold-making of existing parts to 3D scanning and 3D printing of improved parts and geometries.

Repairs

Composite structures are hard to recycle, making it crucial to have efficient repair techniques for the variety of damages that may occur.

We have extensive experience ranging from surface refurbishment and structural repairs to full redesigns of damaged composite parts. Keeping these advanced materials out of landfills is worth the effort.