Open Molding Services
Open molding is a versatile thermoset composite process used to manufacture large, structurally reinforced components.
At Zehrco-Giancola, we combine advanced resin systems with controlled hand lay-up and spray-up techniques to deliver durable, high-performance parts for demanding industrial applications.
Material Development, Testing, Validation, and Problem Solving
A distinction between Zehrco Giancola Composites and other composite manufacturers is the support we provide customers through our dedicated R&D laboratory, Zehrco Giancola Composites. It is, in fact, the largest and best-equipped in-house laboratory in the composites processing industry and can provide you with expertise in materials testing, material selection, and process development, along with the ability to rigorously test and verify product integrity.
How Our R&D Lab Supports Open Molding
A key differentiator at Zehrco-Giancola is our in-house Research & Development and testing laboratory.
- Material Development & Validation
We test and qualify resin formulations and reinforcement strategies to ensure strength, impact resistance, and environmental durability. - Process Optimization
Data-driven trials refine resin ratios, cure cycles, and fiber placement techniques to reduce variability and enhance consistency. - Structural Performance Testing
Internal testing verifies mechanical integrity through thermal, mechanical, and environmental evaluation before production release.
This integrated approach allows us to move efficiently from concept validation to full production while maintaining quality control at every stage.
Material Expertise in Open Molding
Our open molding process is supported by advanced thermoset resin systems engineered for performance:
• Vinyl Ester Resins – Superior corrosion resistance
• Polyester Resins – Cost-effective structural strength
• Epoxy Resins – Enhanced adhesion and mechanical performance
• Phenolic Systems – High heat and flame resistance
By pairing the right resin with engineered reinforcement strategies, we ensure each component meets mechanical, thermal, and environmental requirements.
Explore Our Material Systems
Advanced Open Molding Capabilities
Hand Lay-Up & Spray-Up
Controlled resin application and fiber placement ensure consistent strength, durability, and structural integrity.
Large & Complex Components
Ideal for oversized housings, panels, covers, and structural parts not suited for closed-mold processes.
Flexible Production Volumes
Cost-effective tooling supports prototype development through scalable production runs.
Why Choose Zehrco-Giancola for Open Molding?
With over 50 years of experience in thermoset composite manufacturing, our team understands the structural demands of industrial applications.
End-to-End Support
From material selection and reinforcement engineering to tooling and finishing, we provide comprehensive support throughout the manufacturing process.
ISO-Certified Quality Systems
Our facilities operate under strict quality assurance standards to ensure repeatability and performance consistency.
Application-Focused Manufacturing
We collaborate closely with engineers, OEMs, and procurement teams to deliver custom open molded components that meet exact performance requirements.