About
DS Composite provides performance products and design solutions using innovative and environmentally conscious composites. I maintain a small local shop which is accessible and welcoming.
Composites
Every project is unique and requires a combination of reinforcement, matrix, tooling and manufacturing methods tailored to its specific needs. Some of the methods and materials I have experience with are:
Vacuum bagging, vacuum infusion and compression moulding
Polyester and epoxy resins
Glass, carbon, aramid, basalt, Innegra, flax and cellulose based fibres
Syntactic foams and sandwich type constructions
Thermoplastic composites*
*Thermoplastic composites are remoldable/reformable and thus recyclable when compared to thermosets such as polyester and epoxy resins. The inherently higher toughness of thermoplastics make these composites extremely impact resistant. Thermoplastics also exhibit very good performance characteristics in a marine environment.
About Me
I am a Professional Engineer and have a MASc. with a focus on thermoplastic composites. I’ve been building experimental surfboards for the last ten years and professionally developing composite products for the past three. With the recent addition of a large CNC router I’ve increased my capacity for large scale tooling. I am creating kite-boards with a cradle-to-cradle manufacturing mentality and also offer design services, custom tooling, prototyping and CNC cutting for whatever project you may have.
Services
Design
Computer aided design (CAD) allows accurate realization of concepts in a virtual space. Ideal for determining sizing and layout of features, fastener locations and rapid refinement without costly physical iterations. CAD models are highly effective for communicating concepts to other parties. I have extensive solid and surface modeling experience to assist with your project.
Prototyping
Fabrication of preliminary designs for real world testing. A critical stage in the development of any new product. Whether it’s a low cost proof of concept or a refined design, the ability to see and use the product provides invaluable feedback before full scale manufacturing.
Custom Tooling
The CNC router accurately cuts 3D shapes for moulds or other tools. Low cost prototype tooling from foam or wood, or more durable and production oriented aluminum forms can be created.
CNC Cutting
Parts up to 5’ x 10’ x 8” in size can be cut from materials such as wood, plastic and aluminum. Facing extra large pieces of live edged wood, cutting signs, etc. Whether it’s 2D or 3D machining the dual router heads make for fast tool changes and high efficiency.