Introduction

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.

Challenge

The client’s existing supplier faced major visual defects in their composite parts, specifically white discoloration (“whitewash”) caused by the DICY curing agent in standard prepregs. The issue was visible on highly exposed carbon fiber surfaces and could not be resolved through coatings or rework—an unacceptable compromise for a vehicle of this caliber.

Key Problems:

• White blemishes appearing post-cure in carbon fiber laminates
• Previous supplier unable to meet quality and appearance requirements
• High part complexity with no flexibility in geometry or layup structure

Solution

COTESA, through close collaboration with an innovative prepreg manufacturer (Gurit), gained early access to a new resin system. This breakthrough replaced powder-based DICY with a liquid resin component, eliminating the chemical reaction responsible for the white spots.

The resin system was applied without altering the original component design, making it a seamless drop-in replacement
The new material maintained structural performance while delivering flawless aesthetics

COTESA was the first supplier to recognize and implement this new prepreg resin in series production, gaining a major competitive advantage.

Key benefits included:

• Eliminated surface blemishes without cosmetic cover-ups
• Maintained full mechanical integrity
• Seamless integration into existing part tooling and production
• Exclusive early-mover access to novel prepreg formulation

Conclusion

This solution enabled COTESA to secure the full production order for carbon composite interior parts on the Bugatti Chiron, one of the most exclusive vehicles ever built. The resin breakthrough has since been adapted to other high-end programs.

• Eliminated a major failure mode that competitors couldn’t solve
• Transferred resin innovation into other premium and aerospace applications.