Composite Design & Tooling Services
Plan D Design provides specialist composite component and tooling design services for motorsport, automotive, aerospace, defence, renewable energy and industrial applications.
From lightweight structural components and aerodynamic surfaces to production tooling and mould design, we help clients realise the performance advantages of advanced composite materials while maintaining a practical and cost-effective manufacturing approach.
Our experience traces back to the pioneering adoption of structural composite materials within Formula One, and today we apply that expertise across a wide range of industries, delivering innovative engineering solutions that balance performance, manufacturability and cost.
Structural Carbon Fibre Expertise
We specialise in the design and development of structural carbon fibre components for applications where weight reduction, stiffness and performance are critical.
Drawing on experience gained in Formula One, motorsport and advanced engineering sectors, we support the development of composite structures ranging from lightweight brackets and aerodynamic components through to complex load-bearing assemblies.
Our design approach considers structural performance, manufacturability, tooling requirements and cost, helping clients realise the full benefits of composite materials while maintaining practical production solutions.
Custom Molded Composite Parts
From one-off prototypes to production components, we help clients exploit the advantages of composite materials to solve challenging engineering problems.
Whether the objective is reducing weight, increasing structural performance, improving durability or creating complex geometries that are difficult to achieve with traditional manufacturing methods, we develop composite solutions tailored to the application.
Our services include component design, material selection, laminate development, tooling design and manufacturing support, ensuring a complete engineering solution from concept to production.
Efficient Composite Tooling Design
For suitable applications, we utilise advanced resin-based additive manufacturing to produce high-quality composite tooling quickly and cost-effectively.
This approach can significantly reduce tooling lead times and development costs while delivering excellent surface finish and dimensional accuracy. It is particularly well suited to prototype programmes, low-volume production and projects where rapid iteration is required.
Alongside additively manufactured tooling, we also support conventional tooling methods, ensuring the most appropriate manufacturing solution is selected for each application.
Composite Design Services Overview
Explore our full range of composite design solutions, focusing on innovation and client success.
Structural Carbon Fibre Composites
We tailor structural carbon fibre composites to meet your project’s precise performance requirements.
Composite Tooling Design
Our composite tooling design ensures cost-effective, high-quality molds for your manufacturing needs.
Molded Composite Parts
Custom molded composite parts crafted for strength and durability across various industries.
Our Composite Design Process
Explore our detailed approach to composite design, guiding you through each phase to ensure optimal results and innovative solutions.
Step One: Initial Consultation
Begin with a thorough consultation to understand your project needs, enabling us to tailor composite solutions that align perfectly with your goals.
Step Two: Engineering & Design
Our expert team develops precise composite designs using advanced modeling and simulation techniques to ensure performance and reliability.
Step Three: Manufacturing & Tooling
Leverage cutting-edge 3D printing and molding processes to produce high-quality composite parts and cost-effective tooling tailored to your industry.
Discover Our Composite Expertise
Gain insight into our specialised industry leading composite design services that deliver innovative, efficient, and industry-tailored solutions.
Structural Carbon Fiber Composites
Advanced carbon fiber structures engineered for optimal strength and lightweight performance.
Complex Moulded Composite Parts
Precision-crafted composite components designed for durability and exact specifications.
Composite Tooling Design
Cost-effective tooling solutions utilizing 3D printing for rapid and reliable manufacturing.