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Technology
Innovative Composite Engineering manufactures composite products with prepeg systems.   “Prepreg” refers to composite material that has a catalyzed resin system pre-impregnated into the reinforcement.   This material is then staged or partially cured to remove about 98% of the volatiles resulting in a slightly tacky cloth.   ICE’s prepreg manufacturing methods are capable of higher fiber contents, more precise resin to fiber ratios, higher compaction and lower void percentages when compared to competing wet technologies.
ICE relies on unidirectional carbon fiber for maximizing performance at a given cost.   The “carbon weave” we all think of as carbon fiber actually hurts performance by over 50% due to the weaving of the carbon.   However, the use of these woven goods is helpful for areas needing reinforcing, toughness and increased durability.   The key to developing the highest performance products with the least amount of material is to use unidirectional fibers with the proper alignment for the strength and mechanical properties required.
All incoming prepreg materials are tightly controlled and certified from initial precursors through to the finished product.   Traceability is maintained on all prepreg materials as well as the finished parts throughout the manufacturing process.   The high quality standards and accuracy of our prepreg suppliers combine with ICE’s production methods resulting in superior finished products.
Many filament winders (a wet resin process) market the ability to achieve properties that are very close to those of zero degree unidirectional orientation by winding the reinforcements at angles other than zero degrees.   Prepreg is far more precise and is capable of exact reinforcements at any angle including zero degrees.   However, the manufacturing of certain shapes (especially large or thick-walled tubing) with the proper compaction and interlaminar strength is quite difficult.  This is due to the exponential need for increased pressure in rolling and curing as the diameter of the part increases.   ICE’s proprietary production methods are capable of extremely high compaction of prepregs resulting in the highest quality laminate.   Our low void content (less than .5%) achieves unbelievable performance, durability and interlaminar strength.
ICE has combined the accuracy and performance associated with prepregs with the ability to manufacture larger tube diameters and thicker walled components.   We are the world leader in thick walled prepreg tubing.   Our void percentages are less than 0.5% and our interlaminar strength is second to none in the industry.   See the Capabilities page for our current range of production diameters and wall thicknesses.
ICE chooses to manufacture with prepreg due to it’s superior performance across the board for high tech, industrial, aerospace and recreational composite products.   There are also a number of other benefits to manufacturing with prepregs.  Here are a few: