Why Builders Choose Full-Sized Components
1. Faster Build Speed
Components arrive pre-cut, pre-joined and fit-ready.
Builders simply position and tape them into place — no panel joining, no layout time, no trimming.
2. Reduced Labour & Workshop Waste
Precision nesting reduces off-cut waste.
Pre-joined parts eliminate fabrication steps and reduce the risk of errors.
3. High Dimensional Accuracy
All parts are machined using state-of-the-art CNC routers for consistent, repeatable geometry.
4. Optimised for Modern Digital Workflows
Parts are produced directly from naval architecture or engineering CAD files, ensuring exact assembly fit.
5. Large, Complex Parts Made Easy
Curved, compound and multi-piece assemblies can be delivered as ready-to-use full panels.
6. Engineered for Marine & Industrial Loads
Suitable for primary and secondary structures in high-performance composite builds.
Advanced CNC Kitting Integration
Full-Sized Component Packs form part of ATL’s broader Precision CNC Kitting Services, which include:
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High-accuracy nesting for DuFLEX®, Coosa® and Divinycell®
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Digital flattening of curved surfaces
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Micron-level machining precision
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Component numbering and tabbing
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Complete kit packaging for rapid assembly
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Temporary frames available in plywood or MDF for alignment
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ISO 9001:2015-certified processes
For projects requiring larger prefabricated parts, ATL can supply fully assembled component packs — reducing production time from weeks to days.
Full-Sized Components can be manufactured from:
DuFLEX® Structural Panels
Featherlight® Ultra-Light Panels
FRP Laminates
Coosa® Composites
Divinycell® Foam Cores
Options include:
Square-edge or Z-Joint panels
CNC-machined cut-outs, rebates and detailing
Integrated inserts (PVC, PET, Coosa®, FRP)
Kerfed or curved assemblies
Interior module kits and furniture sets
Marine
Bulkheads, soles, floors and interior modules
Catamaran and monohull structural sets
Decks, superstructures and furniture kits
Transportation
Caravan and RV interiors
Rail and road panel systems
Fleet conversions and lightweight modules
Architectural & Industrial
Structural lightweight partitions
Complex composite modules
Prefabricated bonded assemblies
Full-Sized Components enable builders to:
Reduce fabrication time
Minimise workshop waste
Improve accuracy and repeatability
Achieve faster hull and module turnover
Lower labour costs and handling time
Deliver high-quality composite structures with confidence
ATL’s integrated system — combining DuFLEX®, Featherlight®, CNC kitting, Z-Joining and Full-Sized Components — provides one of the most efficient composite construction workflows available today.
Installation & Secondary Bonding
Concerns sometimes arise regarding secondary bonding between different resin systems. Because DuFLEX® and Featherlight® panels have an inert cured surface, polyester, vinyl ester and epoxy resin systems can all be used to successfully bond Full-Sized Components into place.
Modified ISO 527 double lap joint testing demonstrated that polyester tabbing achieves the same strength on both polyester and epoxy substrates.
Lap Joint Test Results
| Specimen | Failure Load (kN) | Apparent Shear (MPa) | Failure Mode |
|---|---|---|---|
| A | 42.45 | 5.66 | Interlaminar Shear* |
| B | 48.47 | 6.46 | Interlaminar Shear |
| C | 46.50 | 6.20 | Interlaminar Shear |
| D | 47.08 | 6.28 | Interlaminar Shear |
* Interlaminar failure occurred within the CSM layer of the tabbing laminate.
** One specimen showed adhesive failure between tabbing and substrate.
Conclusion: Polyester tabbing performs equally well on both epoxy and polyester substrates — confirming reliable cross-compatibility for secondary bonding.
