Composite Part Design for Thermoset & Thermoplastic Applications
Engineering-driven part design optimized for thermoset composites and thermoplastic molding processes from concept validation to production readiness.
Engineering Design That Supports Manufacturing
At Zehrco-Giancola, part design begins with the end in mind — production.
Our engineers specialize in thermoset composite and thermoplastic component design, ensuring geometry, material selection, and molding strategy align for performance, durability, and cost efficiency.
We collaborate early with OEMs and procurement teams to:
• Optimize part geometry for molding performance
• Reduce tooling complexity and cycle time
• Improve dimensional stability and structural strength
• Select the right thermoset or thermoplastic system
Design decisions are validated before tooling begins — reducing risk and preventing costly revisions later in production.
Design for Thermoset & Thermoplastic Performance
Thermosets and thermoplastics behave differently under load, heat, and environmental exposure. Our design team understands both.
Thermoset Composite Design
Ideal for high-heat resistance, dimensional stability, and structural integrity in demanding industrial environments.
Thermoplastic Component Design
Engineered for repeatability, high-volume production, impact resistance, and tight tolerance control.
We evaluate:
• Wall thickness and rib structure
• Draft angles and parting lines
• Gate placement and material flow
• Reinforcement strategies
• Environmental and mechanical load conditions
This ensures each part performs as intended — not just in CAD, but in the field.
Design for Manufacturability (DFM)
Strong design is only valuable if it can be produced efficiently.
Our team integrates Design for Manufacturability (DFM) principles specific to thermoset molding and thermoplastic processes, including:
• Compression molding
• Injection molding
• Resin transfer molding (RTM)
• Open molding
• Filament winding
By aligning part geometry with the correct molding method early, we help reduce:
• Tooling investment
• Material waste
• Production delays
• Secondary operations
This approach accelerates approval timelines and improves production consistency.
Simulation & Validation Integration
Our part design services integrate closely with:
• Finite Element Analysis (FEA)
• Material testing & validation
• Process simulation
• Tolerance stack analysis
This allows us to validate thermoset composite and thermoplastic parts before production tooling is finalized — minimizing risk and improving long-term durability.
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Our Core Capabilities
We provide engineering guidance across:
• Composite structural design
• Thermoplastic housing & enclosure design
• Industrial component optimization
• Gate and runner strategy
• Tolerance planning
• Reinforcement layout development
• Tooling consultation
- Software Expertise:
CAD Systems: NX, CATIA, SOLIDWORKS
FEA Platforms: ANSYS, Nastran, FEMAP
Composite-Specific Modeling & Advanced Surfacing
Ready to Optimize Your Thermoset or Thermoplastic Component?
Partner with engineers who understand both materials and manufacturing.