NuWave Composites

NuWave Composites 3D Design - Engineering - CNC tooling - Manufacturing
(3)

05/27/2026

Our 3-axis CNC router mills dense polyurethane tooling board to carve out complex sections of a plug. These sections of tooling board are later assembled on a plywood substructure to verify tolerances and to make sure the plug is true.

Manufacturing 3DMachining

05/27/2026

A metal roller is meticulously worked across the wet fiberglass laminate to force out trapped air bubbles and compress the layers tight against the mold. This essential consolidation step ensures complete resin wet-out, eliminating structural voids to guarantee maximum strength and a flawless bond.

05/27/2026

Sections of CNC-machined tooling board are carefully fitted onto a plywood substructure to build a plug. This grid-like framework provides a highly stable, rigid foundation that prevents any shifting or warping during the manufacturing process. Applying an even layer of adhesive ensures each numbered block is locked perfectly into position before moving onto the next steps.

Manufacturing

05/24/2026

Using a chopper gun to spray a resin and chopped fiberglass strands directly into the mold. Hand rollers are immediately worked across the surface to compress the wet laminate and eliminate trapped air.

05/23/2026

Strips of fiberglass fabric are saturated with resin and wrapped around a steel framework to bond it securely to the backside of the mold. This tabbing process integrates the rigid steel structure with the composite shell to eliminate any potential flexing or warping.

05/22/2026

Dry fiberglass fabric is carefully fitted into the contours of the mold before a layer of blue flow media is laid over the top. This specialized mesh is essential for directing liquid resin evenly across the dry reinforcement during the vacuum infusion process. A little adhesive keeps each layer securely in place to maintain precise alignment.

05/22/2026

A CNC router shapes high-density tooling board into precise sections for a plug. Following a digital 3D model, the automated spindle carves exact steps and profiles into the material. These individual sections are then assembled on the shop floor to form the highly accurate foundation for a production mold.

05/22/2026

A rotary buffer is used to bring this mold surface to a high-gloss finish. Buffing the mold to a mirror-like gloss is critical for ensuring cured parts release smoothly without sticking.

05/21/2026

A 3-axis router mills high-density tooling board to produce precise components for a plug by following exact engineering specifications. These individual sections are then assembled to establish the highly accurate foundation.

05/21/2026

A metal roller compresses the fiberglass strands directly into the complex corners of the mold. This squeezes out trapped air and thoroughly distributes the liquid resin into the fibers. The tool is continually worked over to achieve a uniform laminate layer.

05/20/2026

A guide coat highlights low spots and imperfections along the contours of this plug. Manual block sanding smooths down the surface to ensure perfectly straight lines and uniform transitions across every face. This process reveals uneven areas that require further refinement before moving to the next stage of production.

Address

3030 Cockroach Bay Road, Ruskin
Sun City, FL
33570

Opening Hours

Monday 7am - 5pm
Tuesday 7am - 5pm
Wednesday 7am - 5pm
Thursday 7am - 5pm
Friday 7am - 5pm
Saturday 8am - 12pm

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