Why Choose AirBench for the Composites Industry?

In the world of composite manufacturing, precision is everything. Whether you’re shaping advanced carbon fibre components or machining GRP panels, the outcome depends not only on the composite material properties, but also the finishing environment. Dust in the workplace isn’t simply a housekeeping issue; it’s a serious health concern, a compliance risk and, in many cases, a barrier to productivity.

For manufacturers across the UK, effective dust extraction has become an essential part of day-to-day operations. As a market leading composite dust control solution, AirBench is trusted by global brands and used by every UK Formula 1 Team for carbon fibre dust extraction.

Image / AirBench

Challenges of dust in composite manufacturing

Composite manufacturing covers a broad spectrum of processes, from bulk GRP fabrication to the fine trimming and finishing of high-performance carbon fibre components. Each process generates dust with different characteristics, but both present genuine risks.

GRP, or glass reinforced plastic, tends to produce larger volumes of dust during cutting and sanding. Carbon fibre work is often more precise, yet the trimming and finishing stages generate very fine particles. These respirable particles are serious carbon fibre dust hazards, as they can easily become airborne and pose inhalation risks.

Capturing carbon fibre dust at source is critical in all circumstances. Relying purely on personal protective equipment is not an option, as PPE can be intrusive, uncomfortable over long shifts and it doesn’t remove dust from the wider workspace. Operators are more effective, safer and more comfortable when a dust extraction system actively controls contaminants at the point of generation.

Dust extraction in operation

AirBench systems are designed around a simple principle: to capture dust as it is created. In a typical downdraught bench application, composite dusts are drawn down through the work surface and into integral filters. Dust is captured without operator intervention or adjustment. There are no extraction arms to position and no hoods to move into place.

This design is particularly effective because most dust tends to fall naturally. By pulling air downwards, AirBench works with the physics of particulate movement. Clean, filtered air is then returned to the workspace, maintaining temperature and reducing energy loss. The result is consistent performance, reduced airborne contamination and a calmer, more comfortable working environment.

For small to medium composite parts, downdraught benches can provide the ideal solution. They are self-contained workstations without any complex installation process. Users simply plug in, switch on and start work.

For carbon fibre applications, we recommend an AirBench FN type heavy-duty downdraught bench fitted with two-stage F-type filters. This configuration provides a high level of protection against fine carbon fibre dusts, while keeping overall filter costs under control. For seated work, such as intricate trimming or finishing tasks, the FPK type offers the same robust filtration in a configuration suited to bench-based precision.

For GRP processes, where higher volumes of dust are typical, but particle size is often larger, the FN type bench with single-stage A-type filters is generally recommended. This ensures effective capture, maintaining efficiency and cost-effectiveness.

In highly manual operations, such as sanding and finishing, these benches protect the workforce from dust inhalation while potentially reducing the need for intrusive PPE. The balance between protection and practicality is one reason AirBench systems are so widely adopted.

VertEx cross-draught systems and booths

Larger mouldings, panels and assemblies require a different approach. AirBench addresses this need through our VertEx cross-draught systems and modular booths. Drawing dust and fumes horizontally through perforated front panels into internal filters; as modular extraction walls, they can start from a compact extracted face and scale up to create large walk-in dust control booths, enabling manufacturers to create fully extracted areas suitable for substantial composite parts.

For larger GRP components or sizable carbon fibre structures, this configuration provides comprehensive containment. Fitted with F-type filters, VertEx systems offer high-efficiency filtration suitable for fine composite dust. Alternative filter sets allow the same system to be configured for sanding, grinding or fume extraction, offering flexibility for mixed manufacturing environments. The modular design also means systems can be expanded as production requirements change, without the need for a complete redesign of the workspace.

Air cleaning units and scrubbers

Even with effective source capture, some residual dust can remain suspended in the air. AirBench addresses this with a range of air cleaning units and scrubbers designed to manage atmospheric dust. Our MF series air cleaners provide compact, portable or fixed solutions for general room air cleaning. These units gently recirculate workshop air through prefilters and either F8 bag or H13 HEPA filters, depending on the model, to continuously improve air quality.

For larger facilities, AT air cleaner towers are designed for factory environments where existing extraction systems may still leave excess dust or fumes in circulation. These standalone systems handle high air volumes and include integrated pulse-clean systems to maintain filter performance.

In composite manufacturing facilities, where multiple processes operate simultaneously, this layered approach to dust extraction and air cleaning ensures a consistently safe and pleasant working environment.

Ensuring compliance with industry standards

Health and safety compliance is a central concern for UK manufacturers. Effective dust extraction systems play a key role in meeting obligations under the Control of Substances Hazardous to Health Regulations 2002, commonly referred to as COSHH. These regulations require employers to assess and control exposure to hazardous substances, including composite dusts.

All AirBench products are built to order in our factory in the East of England. Systems are assembled from standard modular components, enabling short lead times and consistent build quality. With more than 10,000 downdraught extraction systems in service in the UK and overseas, AirBench has a substantial track record, helping organisations meet both internal standards and regulatory requirements.

Perhaps the most compelling endorsement comes from the use of AirBench products at the pinnacle of performance engineering, with every F1 Team in the UK choosing us for carbon fibre dust extraction. This level of adoption speaks volumes, as motor sport’s reliance on AirBench systems demonstrates confidence in our ability to manage carbon fibre dust hazards effectively.

What customers say About AirBench

Customer feedback consistently highlights our products’ reliability, simplicity and effectiveness. One production manager at a UK composites firm notes that the installation process was “remarkably straightforward”, with the improvement in air quality being “immediately noticeable”. Another customer describes the system as “quiet, efficient and unobtrusive”, adding that operators quickly embraced the change because it didn’t interfere with established workflows.

A factory manager in the aerospace sector commented how AirBench provided “a proven solution rather than a theoretical one”, using filter configurations recommended based on real-world applications. Others praise the low energy consumption and the fact clean air was returned to the workspace without significant heat loss, which is an important consideration in manufacturing facilities.

These reviews reflect a common theme; AirBench doesn’t overcomplicate dust control, rather we deliver practical, engineered solutions that integrate seamlessly into manufacturing environments.