Excel specializes in Advanced Composites, Squeeze Molding, RTM, RIM, Vacuum Forming, LP/LT-SMC, Carbon Fiber, Hand Layup, and CNC Machining. We can help with all your low volume, prototype, and production assembly needs.


Advanced Composites

Advanced Composite Materials (ACMs) are also known as advanced polymer matrix composites. These are generally determined by unusually high strength fibers with  high stiffness, or modulus of elasticity characteristics, compared to other materials, while bound together by weaker matrices. These are termed advanced composite materials (ACM) in comparison to the composite materials commonly in use such as reinforced concrete, or even concrete itself.

CNC Machining

We can CNC machine a wide variety of foam board, from 2 lbs. to 80 lbs. density. (No steel or aluminum)

Squeeze Molding

Also referred to as compression molding, a process of squeezing the core and cavity together to form a part.

Vacuum Forming

Vacuum forming is a simplified version of thermoforming, where a sheet of plastic is heated to a forming temperature, stretched onto a single-surface mold, and forced against the mold by a vacuum. This process can be used to form plastic into permanent objects such as turnpike.

Carbon Fiber

A strong, stiff, thin fiber of nearly pure carbon, made by subjecting various organic raw materials to high temperatures, combined with synthetic resins to produce a strong, lightweight material used in various industries.

RIM – Reaction Injection Molding

Reaction Injection Molding (RIM) involves two liquid components, an isocyanate and polyol, which when combined, undergo a chemical transformation. A technician mixes the two liquids and pours the resultant compound into the mold cavity. Inside the mold, the mixture catalyzes, generating exothermic heat as it solidifies into a stable, lightweight and homogenous final composite product. During the setting process, this exothermic release can result in temperatures up to 300º F inside the mold, yet pressures remain relatively low, typically no more than 50 psi.

Hand Lay-Up Process:

One of the most basic of FRP (fiberglass reinforced plastic) manufacturing processes, Hand Lay-up involves applying and forming each resin/glass laminate layer manually into an open mold until the desired part thickness is achieved. Because of the close control of material application, it is the method of choice for producing many fiberglass parts.

Several curing methods are available. The most basic is simply to allow cure to occur at room temperature. Cure can be accelerated, however, by applying heat, typically with an oven, and pressure, by means of a vacuum. When heat is required for cure, the part temperature is “ramped up” in small increments, maintained at cure level for a specified period of time defined by the resin system, then “ramped down” to room temperature, to avoid part distortion or warp caused by uneven expansion and contraction. When this curing cycle is complete and after parts are demolded, some parts go through a secondary freestanding post-cure, during which they are subjected to a temperature higher than that of the initial cure to enhance chemical crosslink density.

LP/LT-SMC - Low pressure / low temperature

  • Time to Market (Typically 50% faster than other methods)
  • Cost (one-third of the cost of Kirksite or Aluminum)
  • Product Dimensions (offers better stability than other methods)
  • Replicates Physical Properties of normal SMC
  • Product Testing (full DVRP Capable)
  • Surface Quality Superior to Kirksite (Cavity Porosity)
  • Product Adhesion (Equal to typical SMC)