RFQ: Sérac Aero SA-1 carbon fibre roof box - composite shells
Sérac Aero OÜ, Tallinn, Estonia · contact: [name], [phone], [email] · date: 2026-10-26
1. What we are asking for
A quotation for tooling and small-series production of the two composite shells (base and lid) of a premium carbon fibre ski roof box, plus assembly of the supplied hardware. Target first batch 20 units, then 100 to 300 units per year.
Please quote separately:
- Master models and production moulds for base and lid (2 cavities, class A outer surface).
- Unit price of the shell pair at 20, 100 and 300 pieces per year.
- Assembly of hardware (hinges, gas springs, latches, lock, seal, clamps, straps, label) and final inspection, per unit.
- Clear coat finishing (UV-stable 2K clear, gloss) per unit, including colour-matched option (painted carbon).
- Lead time for tooling and for the first batch.
2. Part description
| Item | Value |
|---|
| Outer dimensions | 2100 × 960 × 395 mm (closed) |
| Parts | base shell (floor, sides, nose cap) and lid shell (roof and rear), split by a plane sloping from z = 230 mm at the hinge (y = −500) to z = 185 mm at the tail |
| Construction | carbon/epoxy sandwich, PET foam core 3 mm nominal (wall 6 mm overall), monolithic in bands, flanges and fitting zones |
| Target laminate mass | base 8.7 kg, lid 4.4 kg (zone plan supplied) |
| Outer surface | class A, visible 2×2 twill 200 g/m² outer layer, clear coated; or painted |
| Inner surface | mould-released peel ply or textured, no cosmetic requirement |
| Flanges | integrated 25 mm flange with 9 to 17 mm × 4 mm seal groove on the base, 25 × 3 mm mating flange on the lid |
| Integrated features | two crossbar channels in the floor (z 65 to 68 mm ridge), 8 clamp bosses with M8 inserts, strap anchors Ø30 pads, drain holes Ø8, label pocket, strap slot at the lid rear edge, hinge and gas-spring mounting zones with local reinforcement |
3. Supplied by Sérac Aero
- STEP geometry of base and lid (CAD v7, engineering surface) and the styled A-surface (STL/OBJ, 2100 mm) for the mould master.
- Laminate plan with zones, layups and areal weights (document section 09 and
laminate_v7.json).
- FEA report with load cases (75 kg at 3 g, City Crash 2.3 kN per clamp, lid lift at 200 km/h).
- Hardware bill of materials with manufacturer part numbers (hinges, gas springs, latches, lock, seal, clamps).
- Label artwork and user manual (ET/EN/DE).
4. Process preference
Prepreg in autoclave or out-of-autoclave (OoA) vacuum bag, or resin infusion with a cosmetic outer layer. Please state your process, cure temperature, void content you commit to, and whether the sandwich core is co-cured or bonded in a second step.
5. Quality requirements
- Dimensional: flange plane flatness 1.0 mm over the length, split line gap to lid 0.5 mm max with seal compressed, overall length and width ±2 mm.
- Cosmetic: no pinholes, print-through or bridging on the outer surface in the visible zones; clear coat min. 60 µm dry, UV-stable.
- Mechanical: a cut sample from each batch (floor zone layup) for 3-point bending; first-article shells for the full test plan (static load, clamp pull, City Crash at a test lab, lid pressure test).
- Documentation: material certificates (fibre, resin, core, inserts), cure log per part, serial number per shell.
6. Questions to answer in the quotation
- Which process and materials do you propose, and what is the expected surface quality straight from the mould?
- Mould material (epoxy tooling board, composite tooling, aluminium) and expected mould life.
- Can you integrate the M8 inserts and the aluminium nose block during the lay-up?
- Do you offer clear coating and hardware assembly in-house?
- Tooling cost split between master model, moulds and trimming fixtures.
- Minimum order quantity and price break points.
- Lead time: tooling, first article, production batch.
7. Timeline
- RFQ answers: within 3 weeks.
- Tooling decision: 4 weeks after that.
- First article shells: for lab testing before season 2027/28.
All information in this RFQ is confidential. The geometry files are shared under NDA.