Composite Automation, LLC

Innovative Composites Manufacturing Solutions

PCM Innovations tooling

PCM Innovation and Lucas Industries specialize in precision aerospace integration and offers a wide range of products and services, including design, molds for composite materials and production fixtures.  We have developed a unique expertise in machining composite parts for aerostructure and helicopter, with more than 47 years of manufacturing experience. PCM Innovation offers fully integrated solutions and to our customers, who are world leaders in the aviation, space, defense and transportation sectors.  We can take your concept and completely engineer the solution from the “back of your envelope” idea to a fully functioning tool for production.  Allow PCM and Lucas to become your “in-house” tooling experts on an as needed basis to faciltate project completion.



Innovative Engineered Composite Tooling Solutions

These are just a few of PCM Innovation and Lucas Industries publishable tooling systems. 
Contact us for your private discussion on your applications.
Assembly Jig

Assembly Lines

  • Assembly stations and complete lines.
  • Specialized tooling for aerostructure assembly.
  • Best cost solutions with international partners, managed and controlled with PLM software.
  • Multisite fabrication for faster lead times.
Satellite mold

Tooling for Production

  • Fixtures for machining, trimming, drilling, bonding, riveting, stretching dies, transport, handling …
  • Speciality tooling for fabrication of aerostructure parts
  • Speciality tooling for engine parts machining and assembly
Fuselage Tool

Molds for Composites

Metal molds for prepreg

  • Machined metal : invar, steel, aluminum
  • Electroformed nickel shell: 4 to 6 mm / 0,160 to 0,240 in
  • Thermal regulation system (heating or cooling)
  • Injection and vacuum systems
  • Steel structure with micro regulation system of the surface geometry

Molds with inflatable bladder for complex prepreg shapes

  • Machined metal molds
  • Inflatable bladder in high temperature silicone
Fuselage tool

Molds for Composites

Composite molds for high temperature processes 

  • Prepreg cured in autoclave
  • Out of autoclave prepreg
  • Infused epoxy and carbon fiber cured in oven
  • OPTION : Final machining of surface for higher precision (+- 25 microns / 0,001 in)
  • Reinforced composite materials
  • Thermal regulation system (heating or cooling)
  • Injection and vacuum systems

Molds for automated fiber or tape placement (AFP / ATP)

  • Deposition mandrels
  • Curing tools for autoclave
Fuselage tool

Molds for Satellite

Our unique mold solution ! 

  • Material: carbon fiber and high temperature epoxy resin
  • Standard roughness achieved: 0.4 to 0.8 Ra (16 – 32 rms)
  • Profile tolerance accuracy: +/- 0.0635mm (+/- 0.0025’’)
  • Minimum RMS obtained: 25 microns RMS (0.001’’ RMS)
  • Thermal expansion: under 3ppm per degree Celsius
  • Cost saving up to 40% compared to other solutions
  • Proven and stable method confirmed by independent lab tests
  • Close to 100 sold in the recent years

Past and present mold technology in the industry


  • Solid graphite machined to profile tolerance: high material cost and heavy weight (high cost for air transport)
  • INVAR steel welded and machined to profile tolerance: high material cost, long lead time and heavy weight
Autometrix Advantage Composites Cutting Table

Complex Machined Parts

Production of extra large machined parts

  • Aluminium
  • Steel Alloys (including inconel and stainless steel)
  • Titanium
  • Plastics
  • Composites
  • Foam Core
Composites parts for prototypes and production programs

Composites Parts

  • Carbon or glass fiber
  • Epoxy, vinylester or polyester resins
  • Functional prototypes with assembly
  • Prototype parts in cast resin
  • 3D printing for rapid prototyping
Fuselage Tool

Engineering Services

  • Project management with PLM software allowing multisite team
  • Finite Element Analysis (FEA)
  • Concurrent engineering by web conference
  • Secured file transfer via FTP site
  • 3D printing for rapid prototyping
  • Reverse engineering with Laser Scanner (MetraSCAN)
  • Laser Tracker (API and FARO)
  • CMM Probe integrated in a large 5-axis CNC
  • Photogrammetry (Handyprobe)
  • CMM Arm  (FARO Platinum 6)
  • CE Marking Conformity

CAD Software

  • Catia V5
  • Siemens NX
  • Creo
  • SolidWorks
Fuselage Tool

Technical Workforce

  • Full time resources at client site: we have a vast array of employees that are on site, at our customers, to fill their specialized resource needs. Whether for short term or long term, we’re here to help, and rest assured, we can help you.
  • Permanent design team in our offices
  • Turn key solutions with project management and manufacturing