OUR STORY
Today, A to Z Composites is a fully-staffed machine and composite shop, capable of designing and manufacturing in all phases of development, from prototype parts to precision tooling to full scale production.
Beginning in 1990, while working during the day at aerospace composite shop Harbor Patterns, founder Charles Coffey began experimenting with resin, fiberglass and carbon fiber in his garage. Growing up in a motorsport family, he could see new applications for these materials on watercraft and motorcycles. After building parts for a neighbor's superbike, a friend who worked at Kawasaki pointed out that heavy steel jetski components were a prime candidate for the carbon fiber treatment. After successfully building a carbon fiber engine bedpan, Kawasaki reached out, requesting a modified ignition cover for Baja 1000 racer Larry Roeseler.
These early successes led to opening our first shop as The Fiberworks- building lightweight racing hulls for Kawasaki's professional watercraft racing team. After winning every event at the jetski world finals, we built hulls for Kawasaki, Yamaha, Sea-Doo, and Polaris. Our hulls won every major title in the world from 1991-1996.
In 1999, a move to Washington State and changes in the watercraft industry warranted a return to aerospace. We began building aerospace composite tooling for Heath Tecna and the Navy, including molds for F-16 F-15 and F-35 canopies. Our client list expanded to include Naval Air Warfare Center and we began building carbon fiber parts for UAV (unmanned aerial vehicle) platforms. After focusing on aerospace for 24 years, the materials and techniques we developed led our innovations full circle, back to motorsports.
In 2021, our contact at Kawasaki alerted us to the upcoming reintroduction of the KLR 650 and the need for aftermarket parts. Utilizing our 3-D scanner, 3-D modeling software, and our love and experience with ADV bikes, we developed the parts we wanted on our own bikes- stronger materials, better protection and more features. Reaching out to the ADV community for beta testing, we continue to refine our products to bring you the best carbon motorcycle parts money can buy.
Facility
Our 10,000 square foot facility is optimized to deal with all stages of part production. We can take your idea from sketch to CAD model, prototype through to finite analysis. Our facility is AS9100 compliant and meets all quality requirements associated with the handling and storage of hardware, electrical components and composite materials.
Our lay up and static-free assembly clean rooms, paint booths and curing ovens are maintained to ensure your product is of the highest quality.
WHY WORK WITH A TO Z?
Industry Experience
From a garage in Southern California 30 years ago, to a 10,000 square foot facility with 20+ staff, A to Z has grown into one of the leading precision composite shops in the country. Whether we're building custom jet ski racing hulls entirely by hand, or producing thousands of parts for the military, we're proud of our innovation, efficiency and quality control: Bringing you parts that work- on time and on budget.
Materials
We have access to a wide range of graphite and fiberglass fabric styles, both dry and pre-pregged, that offer a wide range of advantages when used in place of metals, ceramics, or polymers. By using a variety of prepreg carbon fiber, fiberglass, kevlar, thermoplastics and a wide range of adhesives, we create products that are superior to steel in weight and tensile strength, have excellent impact resistance, dimensional stability under temperature fluctuations, and do well in harsh chemical environments.
We work closely with PTM&W for most of our thermoset resin systems, which range in cure temp from 68 to 450° F. A to Z has been utilizing ceramic based pre-preg systems for extremely high temperature applications (up to and beyond 2000°F) with great success.
A to Z is also capable of creating prototype parts and one-off molds using a wide variety of materials including high and low-temp tooling boards, foam, wood and plastic faced plaster (PFP) molds.
Our Facility
Our 10,000 square foot facility is optimized to deal with all stages of part production. We can take your idea from sketch to CAD model, prototype through to finite analysis. Our facility is AS9100 compliant and meets all quality requirements associated with the handling and storage of hardware, electrical components and composite materials.
Our lay up and static-free assembly clean rooms, paint booths and curing ovens are maintained to ensure your product is of the highest quality.
Quality
A to Z guarantees every component that comes out of our shop. From ensuring fiber alignment when laminating, to trimming, testing and final measuring, we ensure every step is completed in a precise and careful manner that ensures product accuracy. Our Quality Control Manager has been certified to perform internal audits by RABQSA