We design, engineer, prototype, and manufacture high-end composite parts and structures for the aerospace, maritime, and medical industries.
ABOUT US
Who we are and what we offer
Lightweight Structures is an ISO 9001 certified advanced composite products manufacturer operating from Pretoria, South Africa. The company was previously operating under the name Lightweight Structures Technology (LST) CC. LST CC was founded in 1998 as a result of the closure of the CSIR-Aerotek Composites Engineering Workshop, effectively commercialising the capabilities of that facility by re-establishing it as a private entity.
Over the past 25 years, we consolidated ourself as one of the few companies in South Africa that specialises in the manufacturing of aerospace-qualified composite parts and structures used by some of the well-known global aerospace companies, maritime companies, and medical equipment manufacturers. We produce components from glass, Kevlar, and carbonfibre materials, utilising both traditional and advanced technologies such as the use of pre-impregnated fibres and resin-transfer manufacturing.
To learn more about benefits of using composites and their applications, visit Composites Lab website.
Benefits of working with us
We understand that the success of our clients is our success. This is why we seek to build long-term partnerships with our clients so we can better understand their needs and serve them to the best of our ability. Throughout the product’s development life cycle, our clients can trust our team’s competence in composite components manufacturing and rely on our manufacturing process to conform to their specifications.
Composites competence
Our successful track record in high-end composites manufacturing spanning over 25 years is built on the continued development and maintenance of internal competencies and capabilities ranging from prototyping and tooling to varied composite manufacturing techniques and impeccable inspection.
Conformity to specs
We understand that our products are used in environments that constantly exert pressure on their ability to perform. Components manufactured by us conform to every check and requirement provided by the client; thus, giving the assurance of the quality needed to deliver the required performance.
Manufacturing reliability
Our commitment to maintaining the excellent reliability of our manufacturing process is delivered through a strong and consistent management team, an embedded culture of reliability in every aspect of our operations through continuous training of our staff, and a well-established maintenance programme.
Effective teamwork
Every product we manufacture is a team effort. Our internal team relationships are built on cooperation, commitment, and trust among the team members. Combined with continuous in-house training this allows us to keep our scrap rates to a minimum and we strive for an on time delivery for every project.
Our markets and services
Industries we specialise in and services we offer
Since the earlier days, as a leading high-end composite structures and composite parts manufacturer in South Africa, we have been offering our expertise and bespoke solutions to advance the state of the aerospace and maritime industries.
We specialise in prototyping and manufacture of composite parts for the aerospace and maritime industries. Our composite aircraft parts are flying all over the world on some of the well-known aircraft. Our composite products have been mounted onto submarines that have seen the deeps of many oceans.
In the last two decades, our composite parts prototyping and manufacturing services have extended into the medical industry. We manufacture equipment covers and table tops for x-ray machines that are now used in many parts of the globe.
Conventional aircraft
Maritime vehicles
UAVs / drones
Medical equipment
Our product development services
From idea to market-ready composite parts and structures – we walk with you every step of a way.
Each new composite parts and structures must go through various stages of design before it can enter full production. We accompany our customers on this journey right from the beginning.
Our involvement starts with the concept design, material selection, and process design. After prototypes have been manufactured, tested, and declared production-ready, we industrialise the composite part, help with the certification (if needed), and set up a full-scale production.
Many of our composite products have been in production for more than 20 years. A culture of ongoing monitoring and continuous improvement has been embedded in our organisation helping our customers to stay technologically relevant and competitive.
OUR CAPABILITIES
Our tools of trade
No design is too complex and no project is too small.
Our experienced team can tackle very complex projects. With a solid track record in engineering, we are capable of designing the most complex structures using the smartest materials and processes available. Over the years, we have designed many new manufacturing processes, some of which resulted in international patents. Our customers can approach us with an idea or a concept, and we will walk with them right through to a finished product that meets all specifications.
We keep abreast of the latest trends in composite materials. Newly available composite materials undergo in-house tests and manufacturing trials to establish suitability of their applications. Our philosophy is to only use high-grade materials with known properties to ensure constant quality during production.
We use a variety of standard and custom-designed manufacturing processes. These include processes such as wet layup, resin infusion, autoclave curing, and casting.
The identification of the correct manufacturing process forms part of the early design stage. It is selected based on customer-defined criteria including operating temperature, humidity, pressure, and product quantity.
We have a fully equipped pattern design and manufacturing facility. Using modern CAD and CNC technologies, we can design and manufacture complex and accurate patterns. Patterns are generally made from tooling board and sealed with a 2K coating. This results in a long-lasting stable pattern that can be stored and reused for many years.
All of our tooling is designed and manufactured in-house to suit the product form and function. Whether creating tooling for prototypes or production components, we always strive for the highest quality and accuracy.
Production of all composite parts and structures is done in-house. Our facilities are divided into various zones to cater for different manufacturing processes. Wet layup, infusion, and prepreg layup are all done in temperature-controlled laminating rooms. Every manufacturing step is controlled with in-house quality checks, which is an integral part of our Quality Management System certified to ISO 9001 standard.
Meet the team
Chris Adrian
Managing Director
Elena Broughton
Financial Director
Xavier Mutakaya
Production Manager
Dr Bennie Broughton
Director of R&D
Jacques Snyders
Quality Systems Advisor
CONTACT US
Contact us to work on your next challenge together
