As shipping bottlenecks and quality issues continue to plague the global supply chain, recent advancements in how composite parts are manufactured are now giving American-based companies the ability to produce their composite parts domestically and still compete on the world stage. Historically, labor-intensive manufacturing processes (like hand-applied prepreg) that were used to produce composites had to moved to countries where labor cost was extremely low when compared to America.

By using a three-pronged approach—that includes dry fiber preforms and resin infusion, use of lower-cost raw materials, and selective use of automation—composite parts can be made affordably while increasing quality and eliminating logistics bottlenecks and cost traditionally seen when manufactured offshore using prepreg.

Dry fiber preforms can be custom-engineered to deliver the required mechanical properties of a composite in a format that is easily put into the final geometric shape with very little labor. Resin transfer molding (RTM) and vacuum-assisted resin transfer molding (VARTM) are processes that also deliver required resins with low labor requirements. Automation can include automated braiders, robots, automated molds/presses, programmable mold heating and cooling, etc.

Using case studies of real-life examples of onshoring, Hawthorn Composites will demonstrate how dry fiber performs and resin infusion can onshore composite parts.

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