Our GRP Manufacturing Case Studies

Designs, develops and delivers subsea buoyancy, protection and insulation for the offshore energy sector, with its own laboratory and testing facilities.

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THE CHALLENGE

Highly technical
product

THE VALUE WE ADDED

Technical support
and development

THE BENEFIT TO THE CUSTOMER

Rapid
delivery

“MPM worked on the project from concept right the way through to first off parts, testing and serial production. Using knowledge of advanced materials, MPM were able to exceed expectations of performance, cycle times and on-time delivery to manufacture a highly technical off-shore infrastructure component.”

Ben Parsons,
Project Engineer, Balmoral

With continual innovation delivering technical solutions to the industry, Balmoral reached out to
MPM as a partner to manufacture a new solution to existing infrastructure by replacing polypropylene moulded parts with high-performance monolithic GRP. Having designed, modelled and computer tested the solution, MPM were able to deliver parts which exceeded the necessary specifications as verified by independent testing by CTL in Galway, Ireland.

Being a highly technical and structurally significant part, materials and process specifications were vital in ensuring the products conformed to the necessary standards for performance and quality. MPM developed an FAI process, checking jigs as well as digital machined glass kits to ensure the technical performance of the parts was consistent and as ready for volume
manufacturing as possible.

Throughout the project, the risk of a failed infusion process was effectively managed using a detailed layup plan and SOPs. Key data such as temperature, pressure, and fill time were recorded on route cards, ensuring full traceability for each part. Each component was also digitally marked with a unique identification number. Additionally, every product was paired with a test sample manufactured concurrently. These samples were laboratory tested to industry
standards, providing technical data on tensile, compressive, and hardness properties. The results significantly exceeded the required levels, ensuring safety and durability under the harshest sub-sea conditions, with a failure point exceeding 4 tonnes.

The success of the project was built on strong communication and partnership between ABI and MPM Durham. From initial sketches through to first-off parts, both teams maintained close collaboration to meet agreed timescales and budget targets. MPM’s ability to deliver on technical design, tooling precision, and quality manufacturing helped ABI elevate their product offering, reinforcing its reputation for quality and innovation in the leisure industry.

Using a form of bagged vacuum infusion, MPM deployed their experience in materials and process knowledge to produce a part thickness in excess of 45mm and a combination of over 200 digitally cut glass-fibre patterns. MPM was proud to have developed a combination of quadaxial glass and glass-based flow medium which enabled the part to be infused in under two hours.

Specialist materials and process knowledge
CNC-cut jigs and templates to support
product quality
In-house/turnkey manufacturing
Strength of supply chain relationships to
shorten lead times and maximise quality