OUR CUSTOM CARBON FIBER AND INDUSTRIAL DESIGN SERVICES
Custom Carbon Fiber Fabrication and repair
Our carbon fiber fabrication and repair ranges from TV Show cars, to flying jet-powered Speeders to supercar customz, we have you covered. Our Los Angeles based boutique design and composite manufacturing firm is owned by Josh Lange, who is an Industrial Designer with a BFA from the Savannah College of Art and Design, who also studied Mechanical Engineering at Cal Poly San Luis Obispo, with over 30 years of experience in custom carbon fiber, composite engineering and design.
carbon fiber fabrication
We feature quality epoxy-based carbon fiber fabrication and repair, using prepreg carbon fiber, the state-of-the-art VARTM, (Vacuum Assisted Resin Transfer Molding process) which is on par with autoclave quality, vacuum bagging, and hand lay-ups, to fit a range of budgets and engineering requirements. We are able to produce painted composite parts very cost effectively or parts with Grade-A surface with either a clear coated exposed carbon fiber surface or surface directly out of mold from prepreg/infusion with no clearcoat for racing and ultimate weight reduction. The raw carbon surface can be polished for an additional fee. We also produce one-off carbon fiber parts without using molds, thus saving clients tooling costs for a one-time part.
Composite Tooling
Whether you want a quick tooling plaster or epoxy mold splashed or more complex tooling with flanges for vacuum processing, we have you covered to meet your carbon fiber fabrication needs. We also fabricate tooling in many other medias such as silicone and urethane, for casting or more organic parts. Our epoxy-based composite tooling enables us to produce painted custom carbon fiber parts very cost effectively or custom carbon parts with Grade-A surfacing for clear coated exposed parts. We also can produce and/or finish work 3D printed molds and CNC'd molds based on CAD models.
composite prototyping
Whether it's a custom jet powered flying Speeder, jetpack carbon fiber assembly, entire supercar bodies, custom carbon fiber wide bodies, splitters, motorcycle parts, marine parts, or sculptures, our quality and attention to details set us apart.
A good example of our process was when we collaborated with Maymen Aerospace to develop their Speeder design in full scale, with Josh Lange hand sculpting the prototype. This enabled their Chief Engineer to make changes to the design in real time as it developed, where CAD would not have had as useful of a visual aide which enabled the client to develop their design very quickly while saving valuable time and money. Lange Customz then fabricated a bespoke carbon fiber body using the finished hand-sculpted prototype and painted it with 2 stage black show worthy finish.
industrial design, product development and R&D
We can help your company develop any product or vehicle type using a hands-on approach to design that Josh Lange, BFA Industrial Design, has perfected over the last 30 years. Hand sculpted models and prototypes can be combined with CAD modeling or with just a simple sketch as a starting point. Functional prototypes such as the flying Speeder, were quickly fabricated using this technique to create a carbon fiber painted prototype body with a concours quality show finish, saving Mayman Aerospace considerable time and money, while meeting their hard deadline.
Vacuum Infusion parts (VARTM)
Save money with the infusion process we use, which produces custom carbon fiber parts on par with those from the much more expensive autoclave process. Our aviation, aerospace, automotive and all other infused parts have an ideal and consistent 60/40 percent carbon to epoxy ratio, which creates parts with a clean surface without the surface pinholes associated with vacuum bagged parts, thus saving time and money on finish work for painted or clear coated parts.
Carbon Fiber repair
Whether it's a structural carbon fiber repair or a cosmetic carbon fiber repair, when it's worth saving a damaged piece, we can handle it. We have repaired camera dolly tracks for Chapman Leonard to exotic supercars and exposed carbon splitters. The streets of Los Angeles can damage aerodynamic supercar parts and we can repair these for less than OEM replacements. The carbon fiber repair of this Ferrari 599 front splitter is typical of a quality epoxy-based composite repair where the carbon is exposed. It was finished with quality clear coat.
exposed carbon fiber parts
Show quality custom exposed carbon fiber parts are our specialty. Quality surfacing can begin with a custom prototype, an existing part or even a part that needs restoration to get a perfect surface to pull epoxy-based tooling from.
Our exposed copper carbon fiber hood and trunk lid were recently featured on the HGTV TV show Celebrity IOU Joyride. Our Ferrari weave carbon fiber corset, blet pieces and battery covers were used for a very high-end client of JetPack Aviation's JB10 jetpack. Epoxy tooling is then wet sanded and buffed to perfection.
carbon fiber and epoxy overlays
We overlay parts using quality carbon fiber and UV stabilized epoxy, followed by quality high-solids clear coat. We can overlay composite-based part made from fiberglass or carbon fiber, steel part and rigid surfaces.
sculpture fabrication and paint
We fabricate sculptures. Josh Lange, who has exhibited his artwork in Los Angeles, has over 30 years of experience and has worked with sculptors such as Yayoi Kusama, Carol Bove and Paul Mc Carthy. We can bring your vision to reality.
Casting resins and leaded crystal
We offer casting services and can cast anything from carbon fiber reinforced parts to food grade silicon molds. Buttons, lenses, handles, almost anything can be cast with exact tolerances, custom colors and transparency not offered by 3D printing. We cast clear DOT approved UV stable urethane, reinforced epoxies, silicon, and even leaded crystal using the lost wax technique. We can print and finish prototypes for mold fabrication.
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