Selected projects

Case Studies

Composite engineering and manufacturing projects across automotive, aviation, UAV, underwater and e-mobility, each taken from the customer's requirements to a tested composite part.

Case study 01 · Automotive

Composite bodywork for an automotive project

Telamorph carried out the structural engineering, tooling and production development for a complete lightweight composite automotive body. The 26 kg body has been manufactured and integrated into several vehicles, and the project is production-ready for a third manufacturing series.

  • 26 kg complete composite body
  • Several vehicles fitted with the body
  • Third series fully documented and production-ready

The brief

The customer supplied the design data. The composite body had to meet defined load and weight requirements, and pass validation for dimensional accuracy, fit, durability, reliability and structural performance before going into production.

How it is built

A hybrid carbon-fibre and carbon-Kevlar construction, optimised for manufacturability and high structural stiffness. The body is designed to withstand the defined service loads without permanent deformation while keeping structural weight to a minimum.

What we did

  1. Structural design and sizing of the composite body against the defined load and weight requirements
  2. Design and manufacture of all required tooling
  3. The first complete prototype body, validated for dimensional accuracy, fit, durability, reliability and structural performance
  4. Industrialisation and low-volume production
Material
Hybrid carbon fibre and carbon-Kevlar
Structure
Lightweight, high-stiffness composite body
Scope
Structural design, tooling, prototype and industrialisation
Status
Low-volume production, ready for a third series

The result

A 26 kg complete composite body, manufactured and integrated into several vehicles. The project is fully documented and production-ready for a third manufacturing series.

Case study 02 · Aviation

Composite structure for an ultralight aircraft

Working closely with the customer's engineering team, Telamorph developed, tooled and built the composite structure for an ultralight aircraft. After certification it went into series production, and it has been manufactured for dozens of aircraft.

  • Certified then introduced into series production
  • Dozens of aircraft built with the structure
  • Thousands of flight hours on several aircraft, over multiple years in service

The brief

The customer's engineering team needed a composite structure that would pass certification testing and then go into series production. It had to carry the loads from the propulsion system and other highly loaded assemblies, and cope with high-temperature zones.

How it is built

Each component uses a highly tailored composite architecture based on its specific load state. Fibre orientations and laminate thicknesses vary locally within individual parts, while stiffening closing panels limit deformation of lightly loaded aerodynamic surfaces. Honeycomb cores and different reinforcement fabrics are selected locally to achieve the required balance of stiffness, elasticity and weight.

What we did

  1. Contribution to the aerodynamic geometry, together with the customer's engineering team
  2. Structural architecture, including load-bearing interfaces for propulsion and other highly loaded assemblies
  3. Structural sizing and laminate definition
  4. Thermal design around high-temperature zones
  5. Assembly design, tolerance definition and preparation for production
  6. Design and manufacture of the tooling, and dimensional control
  7. The first complete prototype structure, manufactured and assembled for certification testing
  8. Industrialisation and series production
Material
Composite laminates, honeycomb cores, locally selected reinforcement fabrics
Structure
Load-tailored laminates with stiffening closing panels
Scope
Complete structure, from architecture to series production
Status
Certified, in series production

The result

A successfully certified composite structure, introduced into series production and manufactured for dozens of aircraft. Several aircraft using the structure have accumulated thousands of flight hours over multiple years in service.

Case study 03 · UAV

RF-transparent radome insert for a UAV

Telamorph developed a compact antenna radome integrated into the composite skin of an unmanned aerial vehicle. It keeps the airframe's aerodynamic contour while letting RF signals pass through the surrounding carbon-fibre structure. After first-article validation, it entered low-volume production.

  • RF-transparent sandwich with an epoxy system
  • Infusion and out-of-autoclave prepreg process
  • Low-volume production after first-article validation

The brief

The customer provided the outer-mould-line geometry, the antenna envelope and the installation constraints. The radome had to preserve the airframe's aerodynamic contour while allowing RF transmission through the surrounding carbon-fibre structure. It also had to meet attachment and sealing requirements, withstand local aerodynamic and vibration loads and keep a controlled laminate thickness.

How it is built

The radome is an RF-transparent sandwich construction with an epoxy system, manufactured using infusion and an out-of-autoclave prepreg process. Material selection, fibre orientation, resin content and wall thickness were defined alongside a preliminary electromagnetic assessment of the material system and geometry. A bonded peripheral flange transfers installation loads to the surrounding structure. Local reinforcements are confined to the attachment perimeter, with joints and conductive hardware positioned outside the active RF aperture. A lightweight RF-transparent epoxy coating provides the exterior finish.

What we did

  1. Material selection, fibre orientation, resin content and wall-thickness definition
  2. Preliminary electromagnetic assessment of the material system and geometry
  3. Structural checks for aerodynamic and vibration loads
  4. Peripheral flange and sealing design
  5. Joints and conductive hardware placed outside the active RF aperture
  6. Manufacturing tolerances
  7. Tooling and process development
  8. First article for dimensional inspection, airframe fit checks, sealing verification and customer-led RF testing
Material
RF-transparent sandwich, epoxy system, RF-transparent coating
Structure
Controlled-thickness RF window, bonded flange, reinforced perimeter
Scope
Complete radome insert, from material selection to first article
Status
Low-volume production

The result

Following first-article validation, the radome entered low-volume production. The completed component kept the specified outer contour and met the installation requirements for integration into the UAV's composite airframe.

Case study 04 · Underwater

Watertight composite enclosure for a ship inspection drone

Telamorph developed and built a pressure-resistant composite enclosure and internal support structure for a compact underwater drone used for ship inspection, and defined how it is inspected and tested for leaks and hydrostatic pressure.

  • Vacuum-infused glass-fibre/epoxy shell with local reinforcement
  • Bonded ring frames and an equipment cradle that keep the propulsion and sensors aligned
  • Staged testing for leaks and hydrostatic pressure

The brief

The customer provided the external geometry and the internal equipment layout. The enclosure had to withstand external hydrostatic pressure, remain watertight and support the propulsion system, batteries and control electronics. It also had to keep components aligned and give access for assembly and maintenance, with particular attention to sealed joints, openings and mounting points carrying concentrated loads.

How it is built

The enclosure is a glass-fibre/epoxy shell with local reinforcement, manufactured by vacuum infusion. Laminate thickness and fibre orientation were defined through structural assessment of external-pressure resistance and buckling. Bonded composite ring frames stiffen the shell, while a composite equipment cradle supports the internal components and keeps them aligned with the propulsion and sensor interfaces. Reinforced mounting areas transfer propulsion loads into the surrounding structure, and the watertight joints use CNC-trimmed flanges and replaceable elastomeric seals.

What we did

  1. Enclosure segmentation
  2. Laminate design, with external-pressure and buckling assessment
  3. Sealing arrangements and maintenance access
  4. Reinforced mounting areas for the propulsion loads
  5. Equipment supports for the propulsion system, batteries and control electronics
  6. Design and manufacture of the tooling
  7. Prototype production
  8. The inspection and staged leak and hydrostatic pressure-testing procedure
Material
Glass fibre, epoxy, local reinforcement
Structure
Pressure-bearing shell, bonded ring frames, equipment cradle
Scope
Complete watertight enclosure and internal supports
Status
Prototype verified against the project requirements

The result

The completed prototype was verified against the project requirements through dimensional inspection, assembly checks and staged leak and pressure testing. It combines the pressure-bearing shell, mounting interfaces and internal supports in a compact enclosure, ready for integration into the customer's ship inspection drone.

Case study 05 · E-mobility

Composite battery enclosure for an electric bicycle

Telamorph developed and built a compact composite enclosure that integrates a removable battery module into an electric bicycle frame. The design and tooling were prepared for repeatable small-series production.

  • Internal supports that keep concentrated loads off the battery module
  • Removable battery behind a replaceable seal
  • Small-series ready design and tooling

The brief

The customer provided the battery envelope, the bicycle-frame geometry and the electrical interfaces. The enclosure had to withstand road vibration, handling loads and local impacts without transferring concentrated loads into the battery module. It also had to protect against water ingress, keep electrical isolation and allow the battery to be removed for service, with thermal clearances, pressure equalisation and a controlled vent path coordinated with the battery-system requirements.

How it is built

The laminate and local reinforcements were developed around road-induced vibration, handling loads and local impact zones. Internal supports and elastomeric pads locate the battery and distribute loads across the enclosure. An overlapping cover flange and a replaceable elastomeric seal provide removable service access and protection against water ingress, and the cable and charging interfaces are built into the design.

What we did

  1. Enclosure architecture and mounting concept
  2. Load transfer into the bicycle frame and internal battery supports
  3. Assembly tolerances and manufacturing requirements
  4. Electrical isolation
  5. Sealing arrangements and removable service access
  6. Thermal and venting provisions, coordinated with the battery-system requirements
  7. Tooling, and prototype production for dimensional, assembly, sealing and functional checks
Material
Composite laminate with local reinforcements, elastomeric seal and pads
Structure
Sealed enclosure, reinforced mounts, internal battery supports
Scope
Complete battery enclosure and mounting
Status
Design and tooling ready for small-series production

The result

The enclosure was integrated with the bicycle frame and electrical system. Checks covered frame fit, fastener retention, gasket compression, connector access and basic water-ingress protection. The design and tooling were prepared for repeatable small-series manufacture, combining structural support, battery protection and service access in a compact composite enclosure.

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