Manufacturers, designers and engineers recognize the ability of composite materials to produce high quality, durable, cost-effective products. Composites solve problems, raise performance levels and enable the development of new innovations. Here are some helpful resources to learn more.

Where are the tools and thermoplastic composite parts manufactured?

Everything we manufacture is produced at our purpose built, 50,000 sq. ft. facility in Commerce City, Colorado. All our parts are fully Berry Compliant.

Who supplies the tooling?

We have full design, development and manufacturing capabilities and can produce any tooling needed. We are also open to use tooling supplied by our customers provided it can be altered to meet our production process.

How much does typical tooling cost?

Tooling costs depend greatly on the size of the part. We generally use steel and aluminum to make our tools and costs mostly depend on the part dimensions. That said, we find our tooling is much more economical than injection-mold tooling or other forming processes.

What tooling is required?

We require machined matched-metal tools capable of withstanding high heats and pressures.

How long are your typical manufacturing cycle times?

Cycle times vary greatly on the part size, geometry, thickness, and material. In most cases our cycle times range from 30 seconds to a few minutes per part.

How is your process automated?

We automate every aspect of the production process, from material layup through forming, and finishing with trimming. In some cases we have designed and built customer machinery specifically for our process. This enables high through-put of parts yet maintain extremely tight tolerances demanded by our customers.

Are your “thermoplastic composites” similar to an injection molded fiber reinforced plastic?

No. Our composites utilize continuously stranded fibers that are custom orientated to maximize strength, stiffness, and minimize weight. A fiber reinforced injection molded part will yield a much lower performing part due to fiber characteristics and orientation.

What is the difference between a thermoplastic composite and a more traditional thermoset composite?

Thermoplastics are polymers that melt upon heating, regaining their solid shape upon cooling. Thermosets however form by undergoing a chemical reaction, known as curing. Once cured, thermoset composites cannot be reformed. Thermoplastics offer many advantages, and are also suited to high volume manufacturing processes.

When you say “thermoplastic composites”, what do you mean?

Composites usually consist of a type of fiber (reinforcement) and a bonding resin (matrix). The fibers can be carbon, glass, aramid (Kevlar®), or many other options. The bonding matrix, in our materials is thermoplastic. Hence, the materials we use are commonly referred to as “thermoplastic composites.”

Can thermoplastics be painted?

Yes, thermoplastics (aside from polypropylene) can be painted from standard industrial grade to automotive Class A finish. Carbon fiber thermoplastic parts can even be powder coated.

Can thermoplastic composites be trimmed?

Yes, the parts are trimmed during one of our last steps of the production process. That said, trimming composites is very tricky and varies widely based on the fiber content, plastic used, part thickness and radius of the trim. We leverage robotic multi-axis water jet cutters as much as possible.

Can thermoplastic composites be bonded to other parts?

In general, yes. Strong bonding of thermoplastic composites is possible with readily available bonding agents. Which bonding material is best to use is determined by the thermoplastic material used to manufacture the part. Some thermoplastics are easier and less expensive to bond than others, but all have readily available bonding solutions.

What design advantages do thermoplastic composites offer?

In addition to custom fiber orientation of the reinforcement, the resin chemistry can be tailored based on your design and performance requirements. Additionally, thermoplastic composites parts can be further enhanced through injection Over Molding of short fiber reinforced or neat thermoplastic resin, providing cosmetic and functional integration, consolidating final part count and reducing fastener and final part assembly times.

How can I convert my existing part design into a thermoplastic composite part?

Our team of composites and design engineers will work with you to understand your project objectives, including a feasibility study, design optimization and simulation. Learn more about how we work with you.

What level of composites knowledge do I need?

Zero. Our team of composite design engineers are experts in their field, and together with our fully integrated process will work with you through every step to ensure the final part achieves your desired objectives.

What quality control processes do you have in place?

Our fully integrated process, from material selection to final part finishing, ensures we have overall control, visibility, and accountability throughout the whole process. Our Oribi Quality Management System (QMS) is our integral internal framework to ensure the highest quality standards are adhered to.

Questions? We would love to hear from you.

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