Composites' U.S. facility employs 55 people
and occupies a 90,000 square foot production
facility where we manufacture high performance
advanced composite components. There is also
a separate 12,500 square foot building available
for confidential projects. Hall Composites owns
an 85,000 square foot production facility in
Breskens, Holland and a 22,000 square foot plant
in Auckland, New Zealand. All of our production
locations produce homogeneous, seamless carbon
structures with optimum weight, strength and
Our production process involves
laying pre-preg carbon fiber into a female mold
or over a male mandrel in the case of tubular
shaped products. Hall pioneered the construction
of seamless, male molded autoclave cured tubes.
With our 151 foot aerospace autoclave, we can
cure one-piece structures up to 150 feet long.
Whether the end product is shaped
inside a mold or over a mandrel, Hall Composites'
engineers optimize the shape with skill and
experience. Once the mold or mandrel is complete,
unidirectional pre-preg carbon fiber is then
applied in multiple directions as required to
support tensile, compressive, and torsional
loads. In Hall Composites highly focused process,
each layer of carbon is carefully debulked (compacted)
before the next layer is applied. This ensures
wrinkle-free laminates even in thick-walled
structures. Even with high ply-count laminates,
thickness predictions are accurate to tenths
of a millimeter due in part to our high-pressure
autoclave curing process. The surfaces are so
smooth, we can apply a clear-coat finish to
the surface with no need for weight-adding filler.
Our expert in-house engineering
department is always available to help meet
your design objectives. Our engineers use finite
element analysis (FEA) in combination with solid
modeling to analyze loads and create the lightest,
strongest, stiffest composite components possible.
Whatever your project entails,
Hall Composites has the experienced staff and
the best equipment to deliver an end product
that fully conforms to your exact specifications.