Addcomposites targets $163 billion composites market with free design software suite

The software suite – comprising AddStack for laminate design, Resin Flow Simulator for infusion optimisation, and Composite Rotor Design Suite (CRDS) for high-speed motor applications – targets explosive growth segments including electric vehicle composites (17.7% CAGR) and aerospace applications (12.8% CAGR). All 3 applications run directly in web browsers without installation, requiring only simple registration.

“The composites industry faces a perfect storm of opportunity and challenge,” said Pravin Luthada, CEO and Co-founder of Addcomposites. “While markets like EV composites surge toward $10.4 billion by 2034, we’re simultaneously seeing 30-50% material waste in manufacturing, 87% R&D project failure rates, and only 5% of composites workers having formal training. By eliminating the $320,000 annual software barrier, we’re not just democratising access – we’re catalysing industry transformation at a critical moment when digital tools can reduce costs by up to 64%.”

Addressing critical industry pain points

The software release targets quantifiable manufacturing challenges that cost the industry billions annually. With aerospace production experiencing 30-50% material waste and resin infusion processes struggling with optimisation issues that lead to costly failures, accessible simulation tools become essential for smaller manufacturers entering high-growth markets.

AddStack revolutionises laminate design through an intuitive visual interface featuring state-of-the-art material databases, real-time mechanical property calculations, and multiple failure analysis criteria including Tsai-Wu and maximum stress theories. The platform eliminates complexity traditionally associated with composite laminate optimisation while maintaining professional-grade accuracy.

Resin Flow Simulator addresses one of composite manufacturing’s costliest challenges – failed infusions. With VARTM processes achieving only 40-50% fiber volume fraction compared to optimal 62%, the simulator provides predictive visualization of resin flow patterns, identifies potential dry spots before production, and optimises inlet/vent positioning to prevent the material waste plaguing 5.7% of industry production.

Composite Rotor Design Suite (CRDS) targets the emerging $3.2 billion high-speed motor components market, enabling design of composite sleeves for motors up to 200,000 RPM. The platform integrates mechanical stress analysis, electromagnetic field calculations, thermal management, and rotordynamic behavior prediction – capabilities previously accessible only through multiple expensive software packages.

Early adopter programme accelerates innovation

“We’re witnessing a fundamental shift in how engineering software is delivered and consumed,” noted James Kuligoski, Head of Business Development and Co-founder of Addcomposites. “With 52% of companies now preferring cloud deployment and SaaS adoption accelerating toward 50% by 2027, browser-based tools aren’t just convenient – they’re becoming the industry standard. Our early adopter program ensures we’re building solutions shaped by actual user needs rather than assumptions.”

The company’s Founding User Program offers exclusive benefits for organisations registering before November 30, 2025 such as priority access to new features and modules before general release, free certification programs valued at €2,000 per user for mastering composite design workflows, direct influence on product roadmap through quarterly advisory sessions with the development team and dedicated support channel with 24-hour response guarantee. The initiative targets the potential user base of 20,000-30,000 academic users across 40+ university programs globally, plus 50,000+ professionals seeking accessible training tools as the industry faces 622,000 unfilled manufacturing positions.

Accelerating digital transformation

The launch aligns with the composites industry’s $2.5 trillion digital transformation investment, where 90% of C-level executives pursue digital initiatives and 63% report positive ROI. Companies implementing digital design tools demonstrate 50-64% cost reductions, 15-20% production rate increases, and 50% waste reduction – benefits previously available only to large enterprises with significant software budgets.

“Educational institutions particularly struggle with software access,” added Luthada. “Universities operate with $25 million in equipment but receive NSF grants of only $500,000-3 million. Free, professional-grade tools enable them to train the next generation of engineers without compromising on capabilities or forcing students to learn on outdated systems.“

The platform supports emerging applications critical to sustainability goals, including wind turbine blade optimisation, lightweight automotive structures achieving 40% weight reduction, and battery enclosures for electric vehicles – markets collectively worth over $35 billion by 2030.

about Addcomposites
Addcomposites Oy pioneers accessible composite manufacturing technology from its headquarters in Helsinki, Finland. The company’s mission to democratize composite engineering spans software development, automated manufacturing systems, and educational initiatives. By eliminating traditional barriers to advanced composite design and production, Addcomposites enables innovation across industries from aerospace to renewable energy. The company serves customers in 20+ countries and maintains partnerships with leading research institutions worldwide.