Composite Manufacturing Challenges OEMs Must Solve in 2025

Original equipment manufacturers (OEMs) working in aerospace, automotive, and energy face relentless pressure to reduce weight, cut costs, and accelerate time-to-market. Materials and production processes are under constant scrutiny, and composite materials continue to be at the center of this transformation. But while composites offer game-changing benefits, their manufacturing processes introduce equally complex obstacles.

One of the most pressing concerns in 2025 is mastering composite manufacturing to meet rising quality demands, regulatory constraints, and scalability expectations. From material consistency to process automation, manufacturers must solve a host of critical challenges to remain competitive.

Navigating Material Variability in Composite Production

Unlike metals, composites such as carbon fiber-reinforced polymers are heterogeneous by nature. Fiber orientation, resin dispersion, and curing parameters must all be tightly controlled to ensure structural integrity. Inconsistent fiber placement or voids during layup can render an entire part unusable.

To address this, many OEMs are investing in automated fiber placement (AFP) and automated tape laying (ATL) systems. These tools enhance consistency while also reducing human error. However, the cost and complexity of these machines can be a barrier for mid-sized suppliers. Engineering teams must evaluate when to automate versus when to refine manual processes with enhanced quality assurance checks.

Managing Resin Systems and Curing Cycles

Resin selection and curing procedures are pivotal to the success of any composite part. Thermoset resins typically offer superior strength but require lengthy cure times, often in autoclaves. Thermoplastics, while easier to process and recycle, may not always meet the mechanical performance needed for structural components.

Curing cycles must be carefully calibrated based on material type, mold geometry, and production volume. Deviations can result in incomplete crosslinking, warping, or delamination. OEMs are now experimenting with out-of-autoclave (OOA) methods to cut energy usage and time without compromising performance.

This shift calls for new process validation models and rigorous material testing protocols, especially for aerospace applications where failure is not an option.

Automation vs. Flexibility: Striking the Right Balance

High-rate production requires automation, but full automation can limit flexibility. For composite components that are low volume or frequently changing in design, rigid automation setups become a bottleneck rather than a benefit.

OEMs must find balance. Some are adopting modular robotic cells with interchangeable end-effectors and software-configurable workflows. This allows production lines to adjust quickly without tearing down entire systems.

Collaborative robots, or cobots, are also entering the scene, assisting human technicians in tasks like material prep, trimming, and inspection. These setups improve throughput while preserving agility on the factory floor.

Cost Management in Composite Tooling and Waste

Composite tooling—especially for large or complex parts—represents a significant cost. Traditional metal tooling requires long lead times and can only be used for specific shapes. Innovations like 3D-printed composite molds and reconfigurable tooling frames are changing that paradigm.

Still, tooling remains a major factor in prototype-to-production timelines. OEMs must optimize part designs not just for performance but also for manufacturability. Design-for-manufacturing (DFM) principles are becoming standard practice to minimize the number of unique tools required across product lines.

Waste is another issue. Off-cuts, expired prepregs, and rejected parts create material losses that directly impact profit margins. Closed-loop recycling systems and better nesting software can dramatically reduce scrap without compromising quality.

Supply Chain Risks and Material Availability

As demand for advanced composites grows, supply chains are under strain. Lead times for specialty prepregs and high-performance fibers have increased. Geopolitical tensions and limited raw material sources add further risk.

OEMs must now consider dual sourcing strategies, regional material stockpiling, and tighter supplier qualification processes. Building strong partnerships with material vendors can lead to earlier access to innovations and better control over pricing volatility.

Additionally, digital supply chain platforms are helping manufacturers track inventory in real time and respond faster to disruptions. These tools provide visibility and reduce reliance on outdated forecasting methods.

Certification Bottlenecks in Aerospace Applications

For OEMs in the aerospace sector, even a small change in composite layup or resin chemistry can trigger a lengthy recertification process. Meeting FAA, EASA, or other international safety standards is resource-intensive and time-consuming.

To streamline this, OEMs are working with regulators earlier in the development cycle. Digital twins and predictive simulations can also accelerate the path to certification by modeling structural behavior before physical prototypes are built.

Still, every new material or process must be proven through rigorous testing, often including fatigue, impact, and thermal analysis. It’s a challenge that slows innovation but cannot be bypassed.

Talent and Workforce Readiness

Advanced composite manufacturing requires a hybrid skill set—technicians must understand not only materials science but also automation, CAD modeling, and real-time data monitoring. The talent gap is growing as older manufacturing methods give way to digitized workflows.

To address this, OEMs are partnering with universities and technical institutes to create training pipelines. Apprenticeships and upskilling programs are also crucial to ensuring the current workforce can meet new demands.

Investing in talent is as critical as investing in machines. A well-trained technician can spot inconsistencies early, adapt to process changes, and maintain equipment more effectively than even the best software.

Conclusion: Solving for Precision with Smarter Tooling Engineering

The road ahead for OEMs is marked by high expectations and complex challenges. Those who can overcome the limitations of traditional methods while integrating smarter materials, processes, and people will lead the next generation of high-performance products.

And at the core of this success lies innovation in tooling engineering, which remains the backbone of composite production scalability, accuracy, and cost efficiency.