| Hand Lay-Up | Approximately 45%–60% | Large panels, covers, fairings, tooling, prototypes, and low-volume structural parts | Flexible laminate design, low tooling investment, and good suitability for complex shapes | Operator consistency, resin distribution, debulking, consolidation, and curing control strongly affect results | Laminate thickness, fiber orientation, void content, resin-rich areas, dimensional accuracy, and surface finish |
| Vacuum-Bagged Prepreg Lay-Up | Approximately 50%–65% | Aerospace-style panels, sporting goods, lightweight brackets, shells, and high-performance covers | High laminate quality, accurate fiber placement, low void content, and repeatable mechanical performance | Requires controlled material storage, vacuum integrity, debulk cycles, and a defined cure schedule | Cure temperature and pressure, degree of cure, fiber alignment, void percentage, and ply-drop execution |
| Resin Transfer Molding (RTM) | Approximately 50%–60% | Brackets, housings, aerodynamic parts, automotive structures, and medium-volume enclosed components | Good two-sided surface quality, controlled dimensions, reduced manual finishing, and repeatable production | Preform permeability, resin flow, injection pressure, mold temperature, and venting must be carefully balanced | Complete impregnation, dry spots, race-tracking, fiber wash, mold alignment, cure uniformity, and part thickness |
| Compression Molding | Approximately 50%–65% | Repetitive brackets, covers, automotive components, and short-cycle structural parts | Fast cycle potential, consistent geometry, and suitability for repeat production with matched tooling | Charge placement, mold temperature, closing speed, pressure profile, and material flow influence fiber movement | Short shots, wrinkles, fiber distortion, flash, dimensional tolerances, surface defects, and cure state |
| Pultrusion | Approximately 55%–65% | Constant-section rods, beams, channels, strips, rails, and reinforcement profiles | Continuous production, high longitudinal stiffness, stable cross-sections, and efficient material utilization | Best suited to constant cross-sections; pulling speed, die temperature, resin impregnation, and tension require control | Profile dimensions, fiber alignment, surface cracking, resin cure, pull force, voids, and cut-length accuracy |
| Filament Winding | Approximately 50%–65% | Pressure vessels, tubes, shafts, cylinders, tanks, and axisymmetric components | Efficient load-oriented fiber placement and good repeatability for rotational geometries | Winding angle, band placement, tension, resin content, mandrel accuracy, and liner compatibility are critical | Fiber coverage, winding angle, liner bonding, leakage resistance, burst performance, voids, and wall thickness |
| Automated Fiber Placement / Automated Tape Lay-Up | Approximately 50%–65% | Large aerospace-style skins, stiffened panels, pressure shells, and complex laminates | Accurate ply placement, programmable fiber angles, reduced manual labor, and traceable process data | High equipment investment; lay-up speed, tow placement, heat management, compaction, and gap/overlap control are important | Ply position, gaps and overlaps, wrinkles, steering defects, consolidation, laminate thickness, and cure quality |