Zak Mobility had a requirement for a lightweight composite springs. The requirement was to be durable, and performance-tuned spring, a critical component for their unique wheel assembly.

Carbon ThreeSixty collaborated on the design and manufacturing, utilising their expertise to integrate features like an aluminium bearing seat and a moulded lip directly into the composite spring, thereby reducing component count and improving assembly efficiency

Carbon ThreeSixty employed compression moulding for prototyping and developed sophisticated tooling for the complex integrated features. A key success was the ability to tune the spring stiffness by optimising the laminate properties – adjusting material type, volume fraction, and fibre orientation – to meet Zak Mobility’s specific performance requirements.

This resulted in the successful delivery of Zak Mobility Composite Springs in three different stiffness specifications, with an additional carbon outer layer variant also produced.