Filament Winding

Filament winding is an automated composite manufacturing process suited to the production of axisymmetric, or close to axisymmetric components. From Tubes to Spheres and any shape in-between this process is suitable for producing very high performance products.

The filament winding process is very flexible in that you can create a wide variety of laminates with full control over the fibre angles. The products can be produced with a wet wound process that allows maximum flexibility for reinforcement and matrix selection. Alternatively components can be wound with pre-impregnated material in the form of a slit tape or a tow preg.

Lentus can design, develop and manufacture a range of products using filament winding, these include:

  • Tension Elements: Tension elements can take the form of rods, bands, straps or tethers. These are used in many areas including cryogenic applications where thermal isolation and mechanical performance is important and electrical applications where electrical isolation is the main driver for a composite part. This type of components also find applications within the aerospace sector for mounting pipework and ducting as well as aircraft interiors.


  • Lightweight Composite Pressure Vessels: These pressure vessels have applications in a range of industries from motorsport, automotive and aerospace, through to subsea, gas storage and research projects. A typical motorsport application would be for a pressure vessel in the sub 1000cc range that has an operating pressure of around 300Bar with a typical burst pressure in excess of 1000Bar. Bladders and diaphragm can be included in these pressure vessels to produce accumulators for pressure damping and pressure compensation.


  • High Speed Rotating Machinery:┬áIn turbo machinery applications there are requirements to react the centripetal forces with a lightweight and strong material. Typical products in this area are magnet retention systems for high speed motors and generator as used in F1 KERS systems, electric vehicles and aircraft actuation systems. These composite sleeves ensure that the permanent magnets on the rotors remain in place at high speeds. Other high speed machinery applications include composite flywheels for energy storage and sleeves for turbo molecular vacuum pumps.


  • Composite Transmission Shafts: Composite transmission shafts allow for the transmission of torque over longer lengths and at higher speeds than would be possible with metallic shafts. These shafts can also have tailored torsional compliance to protect neighboring hardware from torsional vibrations or shock loading. Being composite the shafts are light weight, can be produced to be electrically isolating and can operate in corrosive environments. These shafts find applications in the aerospace industry, prop-shafts for motorsport and automotive industries through to larger shafts for rail and power generation.


The Lentus Team have experience in building quantities of parts from a single product for a privateer motorsport outfit to 10,000 parts for medical applications through to 100,000 parts per year in volume production serving the most demanding of industries including Aerospace and Nuclear sectors.