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About Us > Production Plants
Production Plants

CARF-Models own product is manufactured in one single production plant, G-Force Composites, in Thailand.  Of course there is a lot of accessory and partner product, but our planes are all made under one roof!productionplant1
G-Force Composites Co., Ltd., has been set up in the year 2000. It started from 17 employees at the beginning, who worked in a newly built 350 sqm factory building. Within a year the 350 sqm had to be extended for the 50 workers at that time, and today G-Force Composites houses on almost 4000 sqm not much less than 200 workers. The fast growth was the result of a good product at the right time, produced in a very promising environment.

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Besides a powerful R&D department G-Force has established a very efficient composite production shop. The speciality, painting in the molds, is practiced with every plane. Hand layup tables and vacuum systems have a capacity of 10 airplanes a day.
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2 CNC milling machines mill all the structural internal parts, which get assembled in the mold halves. Some very much loaded parts, such as gear mounts in jet and aerobatic planes, are resin glued in jigs before they are inserted in the parts.
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When the parts of a plane are pulled from the molds an initial QC is made, where all data is entered in a data base, so that we can go back years and still find all relevant data of a part. In the assembly department all planes are fully assembled, wings, stabs fuselages are aligned, canopy mounts and other prefabrications are done to deliver the product with the highest possible prefabrication for the price.

A final Quality Check is made before the plane gets packed. The QC personnel has to go through a full check list and confirm data to be within spec. Meticulously every little cosmetic blemish gets scrutinized and a final polish is applied before parts go into their protection covers and then in the boxes.

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All in all we are very happy to have our production plant so well organized and under control. The dedication of every single worker and the entire management is key for the top notch product delivered to our customers.
Production Info
Composite Production

Composite Production can never be mass production. One mold can produce an airplane every 2 days. This means, from a well maintained mold we can pull approx. 10-12 planes per month. For planes with high demand we run up to 5 sets of production molds at a time. 

The masking and painting of an in-the-mold paint job can take up to 20 man hours, even though there is just bare 8 minutes time to paint a single mold with up to 5 colors.

Lamination of the parts, the vacuum process, installation of structure and joining of molds takes up to 10 hours back to back - for teams of 3-6 skilled workers. And everything is time sensitive as the chemicals tell every worker how fast to work, not his mood...

A 12 hour curing process at 60 deg centergrade finishes the composite production process. But even when the parts are pulled, barely 50% of the total work has been put into a kit, before it is in the box. QC, assembly, again QC and packing takes a big part of the time for a highly prefabricated model airplane. An airplane with the standards CARF-Models is proud to present.