High‑performance composite manufacturing, built for aerospace, defense, mobility, and advanced products.
At Composites Universal Group (CUG), we design, manufacture, and assemble carbon fiber parts for leading programs across California. From flight‑critical structures to Class‑A cosmetic components, our team blends engineering depth with disciplined production to deliver lightweight, repeatable, and certifiable results—on schedule.
Why CUG for Carbon Fiber in California
- Aerospace‑grade quality: Rigorous, documented processes, FAI/PPAP on request, full material and lot traceability.
- Repeatability at scale: Production‑proven work instructions, SPC on key characteristics, serialized builds.
- Speed to market: Rapid DFM/DFX feedback, prototype‑to‑production ramp plans, parallel tool and part development.
- Tight tolerances: Precision trimming and drilling on 5‑axis CNC; typical ±0.25 mm (±0.010 in) features with hard tooling.
- End‑to‑end: Design support → tooling → layup & cure → machining → bonding & assembly → finishing → QA/NDI.
- California‑based: Responsive local collaboration for Los Angeles, Orange County, San Diego, Bay Area, Sacramento, and beyond.
Core Capabilities
Engineering & DFM
- Laminate design, ply schedules, quasi‑isotropic stacks
- Sandwich construction with Nomex®/aluminum honeycomb
- Ply drop management, rib/spar integration, bond design
- Structural analysis hand‑calcs and FEA support (on request)
Tooling
- Soft and hard tooling: additive, aluminum, carbon/Invar®
- Tool design for thermal stability and repeatability
- Cure fixture design for distortion control
Manufacturing Processes
- Prepreg hand layup with autoclave and out‑of‑autoclave (OOA) cure
- Resin infusion/RTM for complex geometries and cost‑effective series
- Co‑bond/secondary bond assemblies, film adhesives, potting and inserts
- Surface finishing: clear‑coat, paint, texture, and branding graphics
Precision Machining & Assembly
- 5‑axis CNC trim, drill, and slot; CMM verification
- Metallic and composite insert installation, PEM®/bonded fasteners
- Kitting, sub‑assemblies, and line‑ready delivery
Quality Assurance & NDI
- First Article Inspection (FAI), FAIRs, and control plans
- Dimensional inspection (CMM, laser), cure logs, travelers
- NDI options including ultrasonic C‑scan and visual; radiography via qualified partners
- Full materials traceability and certificate packages
Materials & Systems
- Carbon fiber: standard/intermediate/high modulus; woven & UD
- Epoxy systems (toughened), BMI, and high‑temp epoxy families
- Hybrid laminates with glass or aramid when EMI/impact dictates
- Edge‑closeouts, core splicing, lightning‑strike mesh (as required)
Industries We Serve
- Aerospace & Defense: flight structures, fairings, doors, ducting, radomes, payload housings
- UAS/UAM/Space: wings, fuselages, booms, panels, antenna structures
- Automotive & Performance: body panels, aero, tubs, crash & energy management components
- Medical & Industrial: imaging structures, robot arms, automation beams, fixtures
- Consumer & Sporting: Class‑A visible carbon, protective housings, frames
Prototype‑to‑Production Ramp
- Discovery & DFM – Requirements, load paths, targets, and risks
- Process Selection – Prepreg/autoclave vs OOA vs infusion/RTM
- Tooling & First Articles – Tool validation, coupon/element testing (as required)
- Pilot Builds – Capability studies, SPC plans, gage R&R
- Production Release – Work instructions, packout, serialization, supply planning
Typical Technical Envelope
- Panel/part sizes: small precision details → large fairings and covers
- Tolerances: features to ±0.25 mm typical; tighter with dedicated jigs and hard tooling
- Surface classes: structural paint‑ready to Class‑A cosmetic weave
- Documentation: traveler packets, inspection reports, material certs, CoCs
Need a specific envelope (autoclave volume, max part size, or certification scope)? We’ll provide a tailored capability statement with your RFQ.
California Programs We Support
- Los Angeles & Orange County: aerospace OEMs, defense primes, e‑mobility
- San Diego: UAS and maritime systems
- Bay Area & Silicon Valley: robotics, space, and high‑tech hardware
- Inland Empire & Sacramento: production scaling and logistics hubs
FAQs
What carbon fiber parts can you make?
Everything from thin‑wall ducts and fairings to thick, multi‑ply structural members, sandwich panels, and bonded assemblies with inserts and hardware.
Do you help with design?
Yes—our engineering team provides DFM, laminate guidance, and joint/bonding recommendations to de‑risk manufacturing and improve performance.
How fast can you deliver?
Prototype lead times typically start at a few weeks depending on tooling and materials. We’ll present an accelerated schedule and long‑lead plan with your quote.
Can you support flight hardware and documentation?
We supply FAIRs/FAIs, inspection reports, and traceability packages. Additional documentation and test protocols are available on request.
What about minimum order quantities?
We support one‑off prototypes through full‑rate production. We’ll scale the process and tooling to your volumes.
Get a Quote
Ready to build carbon fiber parts in California? Share your CAD, drawings, and requirements (loads, environment, finish, volumes). We’ll turn around a manufacturable proposal with schedule, budget, and risk mitigation.
