Technological Expertise

Technological Expertise

At Composites Division, we provide globally competitive light weight eco-friendly yet cost effective composite parts and systems for our Customers in India and Overseas. With cutting edge technologies and 50+ active material formulations, we are the India’s leading Composites manufacturer providing not just composites parts and systems but the full system solution (FSS) to our customers. With 19 patents, our innovative technologies help in reducing weight, driving efficiency, enhancing safety thereby offering high-performance products that set new standards in quality, precision, and performance. While our state-of-the-art R&D labs are fully equipped to formulate, compound and test a range of materials, our product development capabilities enable us in designing, virtual validation, prototyping and tool development. Our competent R&D and Engineering teams are on a constant look out for developing new materials and processes to offer composites of superior strength, high impact resistance, desired fire retardancy and Class A surface finish with a special focus on sustainability.

Sheet Moulding Compounds (SMC)

At Tata AutoComp Composites Division, we develop advanced Sheet Moulding Compounds (SMC) that deliver lightweight, durable, and high-performance materials for automotive and industrial applications. Our SMCs ensure thermal stability, crash resistance, and EMI shielding, while supporting eco-friendly manufacturing through sustainable formulations and recyclates.

Key USPs:
• Lightweight Composites
• Fire, Smoke, and Toxicity Compliance
• Crash Resistance
• Dimensional Accuracy
• EMI Shielding
• Eco-Friendly Materials
• UV Durability
• Paint-Ready Surface Finish

Bulk Moulding Compounds (BMC)

Bulk Moulding Compound (BMC) technology offers high-performance solutions for a wide range of applications, including electrical, automotive, and industrial sectors. With exceptional electrical insulation, high strength, and fire resistance, BMC is ideal for producing durable, lightweight components. Its versatility allows for complex part designs while ensuring dimensional stability. BMC technology is also sustainable, offering eco-friendly options without compromising on performance, making it a preferred choice for demanding applications.

Key USPs

  • High Electrical Insulation
  • 22KV/mm Dielectric Strength
  • UV Laser Printable
  • Low Temp Curable (~120°C)
  • Mouldable for Motor/Coil Encapsulation
  • Tribological Wear Resistance
  • Pigmented for Customized Colours

Hand Lay-up

This involves manually placing layers of reinforcement materials, like fiberglass, into a mold and applying resin. Ideal for low-volume production, it offers design flexibility, high strength, and precision for automotive, industrial and mass transport applications.

Key USPs:

  • Fire, Smoke & Toxicity Compliant Materials
  • Low Volume parts
  • Lower tooling investment
  • Strong & Lightweight
  • Precise
  • Versatile

Pultrusion

We use pultrusion to create strong, lightweight parts. In this process, fibres like fiberglass are drawn through a resin bath and cured in a heated die, forming long, uniform shapes. This technology is ideal for quickly and cost-effectively making durable, high-performance profiles, including solar frame applications, as well as automotive, construction, and other industrial uses. It offers excellent strength and efficiency across various applications.

Key USPs

  • Longer product life than steel
  • Corrosion resistant
  • 20% lighter than steel
  • PU based system for special applications (e.g, Solar Frame)

Filament Winding

This process involves winding continuous fibres, like carbon or fiberglass, around a rotating mandrel, applying resin as the fibres are laid down. The result is a strong, durable part with excellent structural integrity. Ideal for applications requiring precise strength, such as pressure vessels, tanks, and automotive components, filament winding offers high performance and efficiency in production.

Key USPs

  • Lighter weight – 20% than Steel
  • Suitable for long part with variable diameter
  • Optimised design for lighter weight

Resin Transfer Moulding

In this process, dry reinforcement materials are placed into a mold, and resin is injected under pressure to saturate the fibres. The result is a lightweight, strong, and durable part with excellent surface finish. RTM is ideal for complex, high-volume automotive and industrial components, offering precise control, efficiency, and superior material properties.

Key USPs

  • Low Volume Parts
  • Lower Tooling Investment
  • Pigmented Composites Parts

DCPD (Dicyclopentadiene)

DCPD is a cost-effective, fast-curing resin system that offers excellent mechanical properties and resistance to heat and chemicals. This technology is ideal for producing automotive components, including body panels, bumpers, and structural parts. With superior impact resistance and surface finish, DCPD provides an efficient solution for producing lightweight, high-performance parts with reduced production times.

Key USPs

  • Lighter weight (40-60%) than steel
  • Paintable
  • Lower Cycle Time

Foaming for Insulation

We use Foaming for Insulation Technology to create advanced insulation materials for automotive and industrial applications. The process involves injecting a foaming agent into a matrix, which expands to form lightweight, energy-efficient foam with excellent thermal and acoustic insulation properties. This technology is ideal for components like vehicle interiors, engine parts, and soundproofing solutions, offering superior performance in heat resistance, noise reduction, and overall material efficiency.

Key USPs

  • Fire Retardant (0 mm/min)
  • Zero Drop when melting
  • Heat Insulating
  • Good NVH performance

Compression Molding Technology

Compression molding is a high-temperature, high-pressure manufacturing process used to mold lightweight composite parts. It involves placing a pre-prepared compound material (charge) into a heated matched-die metal mold and applying tonnage to form and set the material into a molded part.

Key USPs:

  • Capability to manufacture high-volume parts at low process cost
  • Precise parallelism control
  • Profiled tonnage application
  • Real-time monitoring of process parameters
  • Vacuum control

Bonding Technology

Bonding technology involves joining materials using structural adhesives or chemical bonding, offering improved stress distribution. This helps prevent read-through on surface finishes, enhances durability, and provides a lightweight advantage over mechanical fasteners.

Key USPs:

  • Dispensers with precise chemical mix ratios
  • High-speed robotics for rapid cycle times
  • Controlled bead profiling
  • Minimal squeeze-out

Painting Technology

Painting technology for composites involves the application of high-performance paint on well-prepared surfaces. Key techniques include spray methods in semi-automatic or automatic modes.

Key USPs:

  • Optimized process to achieve a Class A finish
  • Online painting: SMC parts can withstand E-coat and topcoat oven temperatures, enabling painting alongside steel vehicle bodies
  • Electrostatic spraying is possible with conductive composites
  • Flexible primers for superior stone-chip resistance
  • Complete elimination of orange peel is achievable