Turnkey Solutions from a Single Source
Assembly is the final, critical step in the manufacturing value chain, where individual composite, metal and plastic parts become installation-ready, complex products. Carbon Composites Ltd. not only manufactures parts but offers turnkey solutions: we perform structural bonding, mechanical fastening and accessory integration, all under strict automotive quality control.
Our goal is to take the burden off our partners’ shoulders: you don’t need to manage dozens of part numbers – you receive a single, audited-quality unit ready for line installation.
The entire value chain runs in-house: from tooling through RTM and PU-RIM production, via CNC trimming and painting, parts arrive here at the assembly department.
Assembly capacities
How Does Assembly Work?
The process begins with preparation of painted or raw parts and ends with packaging of the final-inspected finished product.
How We Work
Preparation
Cleaning, degreasing and activation of bonding surfaces for maximum adhesion.
Positioning
Precise part positioning ensured with custom-designed alignment jigs and bonding templates.
Joint formation
Application of structural adhesives or installation of mechanical fasteners (bolts, rivets).
Integration
Installation of accessories: locks, hinges, seals, cable channels, lighting units.
Quality control
Dimensional checking and visual inspection of the finished assembly under specialised lighting.
Assembly Examples – Complex Projects
The images below show how complex assembly works in practice: from mould construction to finished railway interior.
Assembly Technologies
For information on joining technologies (structural bonding, mechanical fastening, inserts), integrable materials, hybrid structure construction and the advantages of outsourcing, see the assembly technology guide.
Product Portfolio
Automotive
- VW Amarok – complete hardtop assembly including glazing, locking mechanism, interior trim and gas struts
- MAN Trucks – mudguard assembly with mounting brackets and stiffeners, installation-ready
Railway Vehicles
- MÁV InterCity – seat shell and interior panel assembly with vandal-proof fixings
Custom Projects
- RedBull Promo Car – assembly of the large, multi-part composite box form onto the aluminium frame structure with flange connections and concealed fixings
Why Carbon Composites' assembly department?
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Full vertical integration
Since we also manufacture the parts (RTM, PU-RIM), trim and paint them, any deviation is immediately detectable and correctable at assembly. Single supplier, single part number, JIT delivery – no need to coordinate multiple suppliers.
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Structural bonding and mechanical assembly
Composite-to-composite and composite-to-metal joints with structural adhesives (uniform load distribution). Mechanical assembly with bolting, riveting, snap-fitting. Metric brass/steel threaded inserts installed with CNC precision.
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100% traceability
Every part with a unique identifier (QR code), the entire manufacturing and assembly process documented. Torque reports for bolted joints, visual and dimensional inspection. IATF 16949 and ISO 9001 processes.
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Hybrid structure assembly
Composite-metal-plastic hybrid structures where we exploit the advantages of each material. Aluminium frames with composite cladding, steel mounting points in composite panels, plastic clip system integration.
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Certifications and audits
ISO 9001:2015 quality management system, EN 45545 railway fire protection (HL2 and HL3 levels), customer-specific audits (VW, MAN, Daimler). Documented quality at every step.
Featured Assembly Projects
Frequently asked questions about assembly
Composite assembly is the final step in the manufacturing value chain: individual composite, metal and plastic parts are turned into an installation-ready, complex product. With structural bonding, mechanical fastening and accessory integration, the customer receives a single, audited-quality unit – not dozens of part numbers.
We use three main technologies: structural bonding (composite-to-composite or composite-to-metal, uniform load distribution), mechanical assembly (bolting, riveting, snap-fitting for demountable joints) and insert installation (metric brass/steel threaded inserts into the composite structure).
Metric brass or steel threaded inserts, studs, mounting points, clip systems and bonded fasteners. Insert positioning is ensured with CNC machining precision. For custom inserts, we design dedicated alignment fixtures.
Vertical integration: since we also manufacture and paint the parts, any deviation is immediately detectable and correctable at assembly. Single supplier, single part number, JIT delivery – no need to coordinate multiple suppliers, and no fit risk on the assembly line.
Yes, 100% traceability: every part has a unique identifier (QR code), the entire manufacturing and assembly process is documented. Torque reports for bolted joints, visual and dimensional inspection. IATF 16949 and ISO 9001 processes.
Yes, we can permanently join materials with different thermal expansion and properties. Examples: MÁV IC+ seats (carbon fibre shell + metal frame), VW Amarok hardtop (outer-inner shell bonding with insulating layer), RedBull Promo Car (composite box form + aluminium frame structure).
Our annual capacity is 10,000+ assembled units. We provide JIT (Just-In-Time) delivery directly to the installation point. We can handle sets of 20+ different parts (e.g. VW Amarok hardtop complete assembly).