Introduction

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.

Challenge

The existing approach, prepreg autoclave processing, was rejected due to high costs. A competitive supplier proposed infusion components (RTM light), pressuring the team to offer a similarly priced solution without compromising on quality or performance.

Key challenges included:

• High cost of autoclave prepreg processing
• Need to reduce manual labor and cycle time
• Pressure to compete with lower-cost RTM alternatives

Solution

The team developed a novel press-molded prepreg solution that dramatically reduced labor and material costs:

• Custom short-fiber prepreg sheets were created by layering unidirectional (UD) fibers at 0° and 90° and introducing specific slits for flexibility
• These layers were stacked at varying orientations, placed directly onto a heated mold, and pressed and cured without draping
• The process enabled the creation of deep-drawable, structural components without expensive autoclave setups

Conclusion

The innovative pressable prepreg process enabled the supplier to win the production contract for interior substructures on a landmark supercar. The methodology has since been applied to additional lightweight component programs.

Key outcomes:

• Expanded application of the process to other platforms
• Achieved competitive pricing and cycle time targets
• Delivered lightweight, high-performance parts in line with the brand’s premium standards