top of page


Design, Develop & Deliver

Carbon Fusion Ltd offers an end-to-end service by combining design capability, race car manufacturing knowledge, and infusion expertise all under one roof. This means that customer projects can be reverse-engineered from physical items, designed from scratch, or productised from a current CAD drawing.

Infused Carbon Reinforced Polymer offers numerous advantages over traditional prepreg materials, which can be explored in detail here. Below, you'll find an overview of our services.

Carbon Fusion Design Services


At Carbon Fusion, we specialise in a comprehensive range of services that cater to diverse engineering needs. Our expertise encompasses reverse engineering, original design completion, and crash test simulations. From conceptual design to visualisation and rendering, we excel in providing innovative solutions for lightweight energy-absorbing structures in race cars.

Utilising the Ansys Enterprise product suite, we offer precise and up-to-date finite element analysis (FEA) and computational fluid dynamics (CFD) solutions, ensuring accuracy in our simulations. With Ansys ACP PrePost, we can faithfully replicate complex composite layups on intricate geometries, incorporating the latest material data to account for the variability and complexity inherent in composite structures.

Our capabilities extend to all stages of the design process, including patterns, moulds, and high/low volume manufacturing. This holistic approach allows us to provide a seamless, all-in-one, and cost-effective solution for our clients.

Furthermore, our team is well-versed in 3D scanning and reverse engineering. We pride ourselves on being experts in motorsport regulatory requirements, ensuring that our designs meet the stringent standards of the industry.

Carbon Fusion Develop Services


The detailed design of the part you want to create serves as a blueprint for creating the pattern and moulds.


Carbon Fusion will produce the patterns to make the moulds and then create the 1st Infused Carbon Reinforced Polymer prototype ready for testing at the Cranfield Test Centre (if applicable to the application).

At the Cranfield Test Centre, we will perform load testing on the chassis, sides, footbox, and front/rear roll hoops. To facilitate these tests, specialised push and squeeze blocks are manufactured.

Carbon Fusion can then facilitate a limited production run of the created product. If high-volume production is required, our deliver service is applicable.

Carbon Fusion Deliver Services


Carbon Fusion can productise your infused carbon reinforced polymer product for high-volume production.

Carbon Fusion will contract to deliver an agreed volume of product per month on a rolling agreement.


Carbon Fusion pays particular attention to producing a consistent product every time, ensuring the quality and weight are the same from every batch.

bottom of page