Bright Lite Structures (BLS) is a design and manufacturing company that has developed a patent-pending composite carbon fibre technology.
The BLS solution weighs significantly less than conventional carbon fibre (or aluminium and steel), is capable of make very large 4 meter by 4 meter components, or even larger. It capable of very complex shapes that may not be otherwise possible with conventional carbon fibre or aluminium.
The BLS solution is lower cost than conventional carbon fibre and even aluminium in a number of applications. It is less capital intensive than comparable conventional carbon fibre, aluminium or steel.
The BLS solution has a very short manufacturing cycle, even for very large components. There is no pre-forming required in our process. It is also fast to commercial production and scales easily.
BLS offers a complete solution from design through prototyping to commercial production.
• Front bulkheads
• Rear bulkheads
• Wheel arches
• Truck floors
• Aircraft seats
• Aircraft interiors
Weighs more than 50% less than steel
More than 35% less than aluminium
More than 20% less than conventional carbon fibre
for Conventional Carbon
Fibre: 5 - 45 minutes
for BLS: Can be shortened to under 5 minutes
No pre-forming needed
Best when load case is stiffness or compression driven
Meets or exceeds
Combines recycled & virgin carbon fibre
carbon fibre. No pre-forming needed
Lower tooling costs
RTM or HP RTM require high-pressure presses
BLS low pressure presses enable larger components
Bends near 90 degrees have been achieved in production
Deeper draws obtainable
Different shapes obtained on each side
The patent pending BLS carbon fibre solution uses a sandwich construction. A top and bottom fabric layer of recycled and continuous carbon fibre surround a central core of recycled polycarbonate honeycomb. The fabric sides are impregnated with the BLS resin. This flat sandwich panel is wet compression moulded in a hot tool to form a three dimensional component.
The unique structure of the BLS composites means the components can be stiffer, more flexible and lighter-weight than conventional composite fibre or aluminium.
This approach requires less resin and less carbon fibre than conventional composite fibre, which combine to cut total material costs. There is often significantly less material waste in the BLS component production as well.
The BLS method creates self-joining components & eliminates the need for jigging or separate fixturing to assemble parts.
BLS specially formulated blended resin maintains the performance properties & impact for strength required for vehicle crash.
The BLS process is capable of moulding complex, deep-drawn designs very difficult with aluminium or conventional carbon fibre materials.
Sandwich construction allows each side to be shaped independently into different configurations or shapes.
BLS low pressure presses can mould larger components. One piece can replace 33 pieces for the equivalent aluminium part that then requires assembly.
Bright Lite Structures offers a unique combination of design, prototyping and manufacturing services to producers of durable goods and consumer products. We assist our customers in designing components utilising the propriety BLS technology that will meet their desired performance characteristics. We fabricate prototypes, work out component details, oversee the creation of tooling and manufacture finished components at our production facilities in Peterborough, England.
SPE Automotive Composite Conference & Exhibition and Society of Plastics Engineers Most Innovative Composite Part Material Innovation
We have ongoing working relationships with a number of automotive, commercial vehicle and aerospace companies for design and prototyping as well as volume production of components. BLS is involved with electric car makers as well as makers of other consumer products in exploring solutions for their projects.
Mr. Holman was president and CEO of Industrial Origami from 2003 to 2009. Mr. Holman has extensive experience as a COO and CFO including as a founder of Pictos Technologies, Zing, Photoloft, Northwest Broadcasting and Stainless Steel. Mr. Holman earned a BA from Haverford College, an M Phil from the University of Cambridge and an MBA from the University of California at Berkeley. He is the author of “Do Capital Intensive, High Volume, Continuous Production Manufacturing Methods Inhibit and Deter Product and Process Innovation?”
Mr. Dodworth co-founded Bright Lite Structures. His career in the automotive industry began in 1985 at March Engineering working on Indy 500 chassis engineering.
He moved to Leyton House where he continued to develop his expertise in advanced materials for F1, and then moved to McLaren in 1990 as Composite Engineer to develop chasses for F1 sports cars. This led to work on the acclaimed McLaren Cars F1 road car. Mr. Dodworth then became Chief Designer for International Automotive Design (IAD) in Barcelona where he designed and built multiple concept cars. He joined Hyundai’s European design office and was head of concept engineering.
In 2000, Mr. Dodworth joined Rolls Royce and Bentley Motor Cars, and worked on the original Bentley GT. He also worked as a Studio Engineer for Futura Design and became Bentley Principle Research Manager where he remained until 2011. Mr. Dodworth lectures extensively on composite fibres, including Manchester University, Nottingham University and Madrid University. He also serves on the boards of composite fibre industry associations and has been Co-Chair of the ACE Conference.
Mr. Dodworth has designed, worked on and built chasses including the March Indy 500 car, Leyton House F1, McLaren F1, the first McLaren F1 road car, the Hyundai Coupe Concept, the Cadillac Cien, the Jaguar F Type concept, the Bentley GT concept, the Bentley GT, the Bentley GT convertible, the Bentley Supersport, the Bentley Mulsanne and the Bentley T35 as well as a number of confidential concept chasses.
Chris is a co-founder and Managing Partner of Great Hill Partners. His investment experience covers a broad group of industries including logistics, software, business services, IT and online services, financial services, consumer services, media, cable, telecommunications, education and insurance. Chris serves on the Board of Directors of IntApp, Inc., Credibility Corp., All Web Leads, Inc., and Recruiting.com. He has served on the Boards of Vitacost.com, Inc., SmartMail, LLC, BuscaPé, Inc., Central Security Group, Inc., Ziff Davis, Inc. and IGN Entertainment, Inc., among others.
As an advisor to Bright Lite Structures, Chris brings a curiosity about new technologies and next generation manufacturing processes, in particular the faster and more cost-efficient manufacturing processes that Bright Lite has developed. Chris has worked with more than 50 companies lending advice and help on scaling businesses to meet the demands of enterprise-class customers.
Much of our success in designing and fabricating composite carbon components is dependent upon the collective process-knowledge and knowhow of our leadership and engineering personnel. As a group we have almost 125 years' experience in working with carbon composite materials and 125 years in manufacturing of durable goods, particularly in our focus areas of auto, aerospace and commercial vehicles. All members of our current management and engineering team have worked together in automotive design and manufacturing capacities for at least 10 years and some for more than 30 years.
Interested in knowing how we can help you produce better components, faster and less expensively.
Please get in touch: firstname.lastname@example.org or use the form below.