From prototype to production: unlocking scalable manufacturing for composite roof tiles
Business challenge
Process Innovation
Product Innovation
Sector
Construction and infrastructure
Technology or capability
Automation & Robotics
How targeted engineering support helped Carapace demonstrate a viable path to scaling its technology
Carapace is an ambitious UK start-up rethinking how roof tiles are manufactured - combining advanced composite materials with a decentralised production model.
With proven product performance and strong demand, the business faced a critical scaling challenge. By working with MTC through the Automation and Robotics Technology Accelerator (AURA) programme, Carapace accelerated development of a material injection module - demonstrating how its technology could scale and unlocking a viable route towards industrialisation.
Now I’ve got absolute confidence that the machine that I’ve built is scalable.
Martyn Lucas, Founder, Carapace
Project Challenges
Carapace had already developed an automated pilot system capable of producing composite roof tiles aligned to UK and EU standards. However, scaling that system into a commercially viable solution presented significant technical and commercial challenges.
- Core systems remained at TRL 5-6, limiting confidence in scalable deployment
- Critical subsystems - particularly material injection and multi-mould routing - had not been proven at scale
- The process relied on an abrasive slate-resin feedstock, increasing wear and reliability risks
- The system needed to feed multiple moulds while preventing dripping during movement between tools
To progress, Carapace needed to demonstrate that a key part of its process - material injection - could operate reliably at higher throughput and under realistic production conditions.
MTC’s Solution
MTC worked collaboratively with Carapace, focusing specifically on the material injection module - a critical component in demonstrating scalability.
Applying expertise in mechanical design and manufacturing systems, MTC developed an enhanced solution to resolve the key engineering challenges.
Key areas of focus included:
- Designing for the abrasive nature of the composite material
- Enabling reliable routing between multiple mould tools
- Developing a non-drip sealing solution to ensure process consistency
- Incorporating maintainability, robustness and industrial design principles
MTC’s role was to deliver detailed engineering design and technical insight, enabling Carapace to validate the performance of this critical subsystem.
The key technical difficulties were the abrasive nature of the material… and feeding multiple moulds without drips when moving between them.
Jacob Phillipson, Advanced Research Engineer, MTC
The Outcome
MTC delivered a comprehensive engineering package to support the next phase of Carapace’s development:
- A detailed CAD model and bill of materials (BoM) for the material injection module
- Design outputs to enable manufacture and physical testing
- A design solution ready to support manufacture, physical testing and scale-up trials
This work demonstrated the feasibility of scaling the material injection process, reducing technical risk and providing a critical step towards industrialisation.
Benefits to the Client
Through collaboration with MTC, Carapace was able to:
- Demonstrate a scalable approach to a critical manufacturing subsystem
- Overcome complex challenges in abrasive material handling and process control
- Accelerate development without the need for extensive in-house capability
- Build confidence in the wider scalability of its technology
They bring you in as the team… the depth of resources is what makes or breaks a project.
Martyn Lucas, Founder, Carapace
