Case Studies

A Barcelona workshop manufactures carbon-fiber and fiberglass prepreg parts for yachts and automotive aftermarket components. They previously cut composite sheets by hand or outsourced die-cut parts — slow, costly, and limited in geometry.

Challenges: hand cutting lacked repeatability, so each part varied; carbon dust and frayed edges hurt quality and the working environment; and every new part shape required an expensive die before a single prototype existed.

Our solution:

1. Oscillating knife cold cutting — clean, dust-free edges on prepreg and dry fabrics, no melting or fraying;

2. Intelligent nesting — automatic layout maximizes material utilization on expensive carbon and fiberglass sheets;

3. Die-free prototyping — new part geometries cut directly from CAD the same day, no tooling investment;

4. Vacuum hold-down — thin, slippery prepreg stays locked in place for repeatable accuracy.

Results: part-to-part consistency replaced hand-cutting variation; material waste dropped as nesting packed parts tighter; prototype lead time went from waiting on dies to same-day; and the workshop stopped sending jobs to outside die-cut suppliers.

Customer's words: "Carbon is not cheap, and neither is waiting on tooling. Now we cut a new part the same day we design it — tighter nesting, cleaner edges, and no dies sitting in storage."