FAQs

It is a composite with a sandwich construction. The top and bottom layers contain recycled and virgin carbon fiber, or other fibers, impregnated with a patented resin. These two layers surround a polycarbonate core or other appropriate core material.

How is it different from monolithic composites?

It is a sandwich structure which produces a much lighter-weight product.

Who is using the BLS solution?

BLS is working with a number of well-known aerospace, commercial vehicle, coach, rail, caravan, auto OEM’s and agricultural companies.
BLS has issued patents and patent applications in the US, Europe and Asia. The patents cover a broad range of elements of the BLS invention, as well as managing heat release from epoxy, and PU resins.
The BLS solution weights up to 50% less than steel components; up to 35% less than aluminum and up to 25% less than monolithic composites.
Components use less continuous and discontinuous fibers. Fabrication is an automated/robotized process with minimal labor required. Production components have been benchmarked as competitive with aluminum components.
It is best used when the dominate load case is stiffness or compression driven. The BLS solution is not the best solution for tensile applications.
Because its sandwich construction creates an “I-section”, BLS components are very effective at absorbing the energy from an impact. Our composite compares well with the energy absorption of monolithic carbon fiber, and the overall joules per gram of the BLS solution is lower due to the weight of the core.
The BLS solution uses both continuous and discontinuous fiber and there is no pre-forming. These factors allow bends near 90% to be achieved in production of components.
It uses recycled fiber and recycled cores. BLS components can be recycled depending on whether it is cost effective or not.
It has better bending stiffness than monolithic composites, aluminum or steel because it has an increased I-section created by the sandwich structure of the component.
At the load point, stress will follow the stiffest area. The BLS solution has increased thickness at the corners as this is the stiffest point.
With our sandwich structure, each side can be shaped independently. This also makes it easier to incorporate fixturing.
BLS has produced components that are 2.5 meters by 3 meters, but larger components are possible. The only limitation is the size of the press. To make larger components, a relatively low-cost press is required. RTM and HP RTM need high clamp pressure requiring very large and expensive presses and making larger components less economical.
Because the BLS solution is not as brittle, deeper draws are possible exceeding that of a typical aluminum component.
  • • Commercial aircraft seatbacks, luggage compartment covers, floors and other interior components
  • • Commercial vehicle floors, doors, roofs and other components
  • • Coach floors, doors, sides, roofs and other components
  • • Rail and street car floors, HVAC Mounts, doors, roofs and other exterior components. Seating and other interior components.
  • • Automotive floorpans, front & rear bulkheads, wheel arches, rails/rockers, Class A bonnets
  • • Auto EV battery enclosures, Battery lids
  • • Caravan floors, doors, sides, roofs and other components
  • • Tractor structural mounts
BLS composites are used in commercial aerospace products including aircraft seats backs, interior panels and floors.
For aerospace applications such as seating and other interior applications, BLS has several solutions which meet the FAR 25.853 fire, smoke and toxicity standards. Results are shown under Test Results > and are also available on request.
BLS has developed solutions which comfortably meet the FAR 25.853 peak and total heat 65 kW Min./m2 standards. It also meets these standards whether they are painted or “stickered”.
BLS aerospace seat backs have sufficient stiffness to comfortably exceed 2,000 Newtons.
Compared with seat backs made with phenolic resins, BLS aircraft seat backs made with epoxy polyurethane resins are much stiffer, have been benchmarked as weighing up to 40% less. To get equivalent stiffness from an aircraft seat back made with a phenolic resin requires significantly more fiber and phenolic resin, increasing the component weight. In addition, BLS solutions do not face the environmental issues of phenolic resins.
BLS rail components currently meet the EN 45545 R1 and R7 HL1 and HL2 standards. BLS is currently in the process of addressing the HL3 standard. Results are shown under under Test Results > and are available on request.
BLS has been BSI certified to ISO 9001:2015 under certificate FM697471.
Yes. Bright Lite Structures has a Quality Policy which can be obtained from Darren Butcher, Quality Manager, at dbutcher@blstructures.com.
Yes, it’s possible to apply an e-coating up to 190 degrees Celsius.
Most BLS applications are used structurally. However, class-A finishes are available and have been successfully used on exterior components.
BLS solution has been extensively tested to identify its characteristics.
The BLS sandwich construction uses less carbon and other fibers than conventional composite products. Of the carbon fiber used in the production, often more than 50% is recycled material. The polycarbonate material used to bond the sandwich is comprised of 70% recycled polycarbonate. Depending on the cost parameters, BLS components can be recycled. In addition, our low-pressure process uses less energy in manufacturing than conventional composites, aluminum or steel.
One BLS solution uses a tongue and grove design which creates very accurate joints, avoiding the need to spot weld flanges used in most steel, aluminum component and other metallic structures. The ability to make small adjustments makes the overall structure extremely accurate.
The sandwich construction is more effective at preventing sound transmission compared with other commonly-used monolithic materials such as carbon fiber, steel and aluminum. The core effectively “traps” sounds and acts as a barrier. Depending on the application, this reduces the requirement for sound deadening materials.
The core of the BLS sandwich construction effectively acts as a thermal barrier reducing the requirement for additional thermal insulation. BLS has done testing for the ISO Section 8.3, 1496:2:2018 thermal insulation standard. Results are available under Test Results >.
Pigments can be added to create darker colors.
No pre-forming is required reducing total cycle time and cost. The BLS solution always starts with a flat sandwich which is then molded into a complex 3-dimensional shape in a single step.
Current total cycle time can be as little as five minutes.
Because of the deep-drawn designs, larger components and independently shaped sides, BLS technology has been benchmarked as having over an 80% BOM reduction compared with conventional aluminum solutions.
At relatively low cost, BLS can relatively easily produce 100s of thousands of parts, both large and small, of all sizes annually.
Depending on the number of components in each tool, it is relatively simple to scale up from 100s of units to 100s of thousands of units.
It can take as little as six months from the approval of the prototype until the beginning of volume production.
BLS uses low pressure presses and other equipment which require lower capital investment. There is no pre-forming equipment required
Compared with RTM, steel or aluminum tooling, the BLS tooling is relatively inexpensive.
BLS offers its clients a range of services from the design of components to each client’s specifications, to tooling and prototyping, volume production and delivery of finished components on schedule.
Usually, a sketch, a package or CAD is all that is required to get started. Contact one of the following individuals at Bright Lite Structures Otto Ori, Joest Hoekstra or Emmanuel Girelli for additional information.
The BLS manufacturing facility is located in Stamford, an hour north of London. Supplying components to Europe is relatively straightforward.

Bright Lite Structures LLC. • Patented Technology • Unit 3, Uffington Road, Stamford, Lincolnshire PE9 2BF, UK
Corporate: 90 South Park • San Francisco, California 94107 • US

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