Semi-Production: Limited Run Composite Manufacturing

Semi-production, also known as limited production, is the manufacturing approach for programs that need more than a one-off part but don’t yet justify full-scale mass production tooling and processes. It’s the middle ground between prototyping and high-volume manufacturing — and it’s where a lot of the best-run composite programs actually live.

Custom Composite Technologies has built limited production capability into its process from day one. We fabricate and store tooling specifically to support repeat builds, so when your program needs 10, 50, or 200 dimensionally consistent parts, we can deliver them with the same tight tolerances and finish quality as your first article.

Why Choose Limited/Semi-Production

  • Repeatability without the overhead of mass production — get consistent, production-quality parts at moderate volumes without investing in high-volume tooling and automation.
  • Tooling fabrication and storage included — we build and maintain your tooling between runs, so you’re not paying to remake molds every order.
  • Ideal for evolving programs — semi-production suits projects still being refined, avoiding the cost lock-in of hard tooling for a design that may still change.
  • Scalable relationship — as volume grows, we help you evaluate whether it’s time to move toward higher-volume tooling and processes.

How Semi-Production Works at CCTI

  1. Volume & Timeline Assessment — We evaluate your expected run size and cadence to recommend the right tooling and process approach
  2. Tooling Fabrication — We build molds and jigs designed to hold tolerance across repeat builds (see Tooling Fabrication)
  3. Ply Cutting & Kitting — Material is cut and kitted in advance for consistency and efficiency across the run (see Ply Cutting)
  4. Production Runs — Parts are built to the same spec, run after run, with quality checks at each stage
  5. Tooling Storage — We store your tooling between runs, ready for your next order
Let’s Discuss Your Limited Production Program

FAQ

Semi-production, or limited production, refers to manufacturing composite parts in repeatable but moderate volumes — more than a one-off custom part, but less than full mass production. It typically uses dedicated tooling that’s fabricated and stored specifically to support repeat runs.

Semi-production (limited production) uses composite processes like vacuum infusion, wet layup, or pre-preg with tooling sized for moderate run volumes, while mass production typically involves higher-volume automated processes and tooling designed for very high part counts. Semi-production offers a lower up-front tooling investment for programs that don’t yet need mass-production scale.

There’s no fixed number — it depends on part complexity and program needs. Generally, limited/semi-production covers runs from roughly 10 to a few hundred parts, where consistency matters but full-scale production tooling isn’t yet justified. Contact CCTI to discuss what makes sense for your specific volume.

Yes. CCTI fabricates and stores customer tooling specifically to support ongoing limited production programs, so you’re not paying to rebuild molds for every order.