The industrialization of high-performance composite materials requires far more than simply having advanced technologies available: it takes process know-how, adequate production infrastructure and the ability to sustain industrial volumes over time.
Bucci Composites has built its market positioning around press-based processes—particularly HP-RTM and PCM—integrating these elements into a robust, scalable manufacturing model.
What we do: Industrializing press-molded composites
Bucci Composites has well-established expertise in press molding polymer-matrix composite materials, with a specific focus on HP-RTM (High Pressure Resin Transfer Molding) and PCM (Press Compression Molding) processes applied to structural and aesthetic carbon-fiber components.
The experience gained enables us to manage the entire component development cycle, from engineering through to serial production, optimizing geometries, laminate layups and forming and curing cycles according to the required performance and production rates.
Press molding makes it possible to obtain components characterized by high structural efficiency, control of resin content, dimensional stability and process repeatability, making it particularly suitable for complex, long-term industrial programs.
Press fleet and industrial infrastructure
Bucci Composites’ production capacity is based on a well-structured industrial asset base, designed to support serial manufacturing and large-size components.
The facility is equipped with six presses dedicated to HP-RTM and PCM processes, configured as follows:
- 2 presses of 2,500 tonnes
- 2 presses of 1,500 tonnes
- 1 press of 800 tonnes
- 1 press of 60 tonnes
This equipment is complemented by an 800-tonne automatic preforming unit, a key element for composite industrialization when the project allows it.
Automatic preforming: accelerating industrialization
When the component design allows, Bucci Composites integrates automatic preforming systems into the production process.
Preforming enables us to reduce material preparation times, improve lay-up repeatability and increase overall production rates, significantly contributing to reduced process variability and scrap.
The combination of automatic preforming and press molding is one of the key factors in making composites a truly industrializable solution suitable for high volumes.
Automotive: serial production of structural components
In the automotive sector, HP-RTM and PCM processes are now central to making carbon fiber compatible with serial production.
Bucci Composites operates as an industrial partner for the development and production of high-performance structural components, supporting customers from the co-engineering phase through to production.
The goal is to combine high mechanical performance, production continuity and industrial scalability, making composites a practical solution for complex automotive programs.
Aerospace: established standards and market evolution
In the aerospace sector, Bucci Composites has historically operated through the autoclave process, which still represents the benchmark standard for manufacturing carbon-fiber structural components for civil applications and helicopters.
At the same time, the sector is progressively opening up to alternative processes to autoclave, including press molding, with the aim of improving industrial efficiency and reducing cycle times, while keeping quality and reliability requirements unchanged.
In this context, the experience gained by Bucci Composites in press-based processes for automotive applications represents a solid technological foundation, ready to support future needs in the aeronautics sector.
A manufacturing model designed for scalability
The integration of press fleet, automation and quality control enables Bucci Composites to sustain high production rates with a high level of process stability. The manufacturing model is designed to meet the needs of OEMs and Tier 1 suppliers, ensuring repeatability, traceability and industrial continuity.
The combination of process know-how and large-tonnage presses makes it possible to support long-term, structured industrial programs through an approach focused on industrial composite manufacturing, where production capacity and technical expertise progress in an integrated way.
For more information about our processes, the Bucci Composites team is available to help.
