Composite layup tooling — Defence
Printed layup mandrels and wash-out cores for composites. Delivered for a defence client in Dahej.
- Location
- Dahej
- Year
- 2023
- Duration
- 19 weeks
- Team
- 8 engineers
- −70%
- tool lead time
- −74%
- tool cost
- 129
- tools
The challenge
Conditions on site — heat, dust, vibration and patchy connectivity — had defeated two earlier attempts at this in defence.
What we built
A phased rollout: a measured pilot first, then scale-out. The core runs on FDM with Wash-out cores, integrated into existing systems through Carbon fibre.
Delivery timeline
Phase 1
Discovery sprint and site survey
Phase 2
Prototype built and tested in the Motera lab
Phase 3
Pilot on site with before/after measurement
Phase 4
Scale-out, training and handover
Highlights
- Designed, built and supported from Motera, Ahmedabad
- Operator training delivered in Gujarati, Hindi and English
- Safety case reviewed with the client's EHS team
- Documentation, drawings and source handed over at close
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