Case Studies

Boosting CFRP Frame Production Efficiency

A major aerospace OEM aimed to increase efficiency and reduce costs in the production of carbon fiber reinforced polymer (CFRP) fuselage frames.

Streamlined Wastewater Tank Manufacturing

A leading aerospace supplier sought to optimize the production of composite wastewater tanks for civil aircraft, aiming to reduce costs, labor, and manufacturing time while improving product quality and consistency.

Lightweight Efficiency for a High-Performance Interior

In 2011, COTESA partnered with a performance automaker to develop interior trim parts for a flagship supercar. The client required a cost-effective solution for a structural subcomponent that would remain visually concealed, yet offer the performance benefits of a CFRP-like material.

Ballistic-Protected Cockpit Partition Wall for the Airbus A380

As part of the Airbus A380 development, COTESA was entrusted with designing and producing a ballistic-protected cockpit partition wall, a component that needed to combine structural integrity, ballistic resistance (B4 class), and aesthetic finish, all while maintaining strict aerospace weight constraints.

Revolutionizing Transmission Shaft Performance

In applications ranging from the Airbus A380’s flap actuation system to helicopter tail rotors and high-speed sports cars, transmission shafts must withstand extreme torque or rotational speeds. COTESA’s solution reimagined shaft production, delivering aerospace-grade performance in a scalable, cost-efficient format.

Advanced Composite Battery Housing

An innovative electric aircraft manufacturer was seeking a lightweight, high-performance solution to safely contain the high-energy batteries used in their next-generation vertical take-off and landing (VTOL) aircraft.

Advancing Sustainable Air Cargo with Composite Innovation

COTESA, a trusted manufacturer of high-performance composite components for the aerospace and transportation industries, was selected as a key development partner by a European company pioneering a new generation of sustainable air cargo containers.

Solving the Surface Challenge for a Hypercar Interior

In 2014, a prestigious OEM sought a new partner to deliver flawless carbon fiber interior components for its next-generation hypercar. The challenge was steep: deliver not only complex geometry and luxury finishes but meet near-impossible aesthetic quality standards—where imperfection was not an option.