From prototypes to performance: Composites company makes inroads to new markets

Calian (Ottawa, Ontario, Canada) was initially formed in 1982 and through internal growth, expansion and acquisitions has grown into a global company with more than 4,500 employees. The company works on a range of solutions from cybersecurity to communications to manufacturing within a variety of industries including communications infrastructure, healthcare, training, defense and space. Within Calian’s Advanced Technologies division lies its advanced manufacturing and engineering services capabilities. Calian Composites Ltd. (Saskatoon, Saskatchewan, Canada), a composites-focused subset of the Advanced Technologies division, benefits from Calian’s immersion in this broader network, enabling streamlined collaboration on projects that require integrated sensors, embedded systems or custom electronics.

Recognized as a qualifying facility in CW’s 2024 Top Shops benchmarking survey, Calian Composites has emerged as an example of how focused specialization within a diversified corporation can yield successful results.

From reflectors to a range of complex components

Calian’s foray into composites began in the realm of satellite communications (SATCOM). Initially formed as an internal R&D initiative aimed at improving reflector designs through the use of composite materials, the team’s expertise in precision structures and large-format manufacturing quickly grew into a standalone capability. Today, while reflectors remain a cornerstone of its product offerings, the composites division’s portfolio has expanded significantly to include defense vessels, autonomous vehicles, drone systems and structural components for civil infrastructure projects.

“With our background in SATCOM where tolerances are demanding, understanding mechanical requirements and maintaining a high attention to detail is really important to our solutions,” says Michael Rennie, director of operations, Calian Composites. “We’ve built an expertise around designing large structures and fabricating assemblies to exceptional tolerances.”

Manufacturing versatility

At the core of Calian’s composites success is its diverse and ever-expanding set of manufacturing capabilities. Its facility in Saskatoon is home to approximately 50 professionals, including engineers, technologists and fabrication staff, with an infrastructure robust enough to handle both prototype and high-volume production.

Rennie explains that the division started with vacuum infusion because of its cost-effectiveness and high quality. “Vacuum infusion allows you to achieve high-quality parts without the need to invest in unnecessary expensive equipment,” he says.

Over time, Calian Composites added a resin transfer molding (RTM) line and also does wet layup and prepreg work. It even recently acquired a three-axis CNC router that it is using to produce its own RTM molds. Rennie says that adding mold manufacturing to the company’s in-house capabilities enables faster iteration and better control over the production cycle. Additional capabilities include an automated cutting table — used for both internal kit preparation and external kitting services — as well as in-house painting and gelcoat finishing.

“We are also beginning to explore compression molding for smaller components and higher cycle rates,” Rennie says.

But where Calian truly distinguishes itself is in smart structures. Working closely with the Advanced Technologies group, the composites division integrates embedded electronics and sensors into parts — sometimes for structural health monitoring, sometimes for heating systems like deicing, and increasingly for applications such as antenna bases and radio frequency (RF) signal transmission.

The company has recently been exploring using special integrated antennas to create 5G-compatible composite structures for the automotive industry. This combination of technologies can enable these components to function both as a structure and as an RF transmit/receiving device.

“This is where being part of Calian’s large network is great,” says Rennie. “Something that Calian’s been a huge proponent of is enabling cross-business unit developments. This allows us to incorporate our composite capabilities with the other advanced technologies Calian offers in order to solve complex problems.”

Calian’s composites division supports a diverse mix of industries, with ongoing programs in SATCOM, defense, civil infrastructure and specialty transportation.

One example is a fleet of autonomous drone target boats manufactured for use by the Canadian and Australian Navies. These vessels are deployed at sea to replicate various naval tactical patterns for radar and threat detection, requiring robust construction to withstand high G-forces and ocean conditions.

“These targets are deployed off of naval ships at full speed and are capable of pulling upwards of 30 Gs,” Rennie says. “Making sure that laminates are consolidated properly, voids are minimized and that everything is built to specification is critical.”

On the civilian side, Calian is targeting mining as a growth sector. In a recent development, the team produced a prototype composite door for an underground electric mining vehicle. The new glass fiber-reinforced polymer door offers corrosion resistance, thermal insulation and significant weight savings over the existing aluminum version at a comparable cost.

“Due to the harsh environments found in many mines, composites offer a number of great solutions,” says Rennie. “For example, if you look at underground mining vehicles, a lot are battery-powered; a solution that can reduce weight, prevent corrosion and offer natural thermal insulation is becoming more and more appealing to the mining sector.

“It’s also a really good example of where composites shine when compared to traditional materials,” he continues. “You can easily combine these unique materials and get so many benefits in one streamlined manufacturing process.”

When it comes to materials, Calian Composites has widespread experience with a variety of fibers and matrices. For high-end SATCOM and aerospace applications, the company relies heavily on carbon fiber and epoxy systems, often incorporating foam or custom core materials. For less-demanding applications where cost is a factor, it often turns to fiberglass with polyester systems.

The company is currently exploring the integration of honeycomb core structures — particularly carbon fiber-based options that may be manufactured internally. “We’ve seen a bit of market gap for carbon fiber-based core structures that are cost-effective,” Rennie says. “We’re exploring whether we can develop our own range of custom core designs.”

Continuous improvement and collaboration

Key to Calian’s success is its commitment to learning, growth and feedback. With a workflow that includes frequent new product introductions and rapid prototyping, the team operates in a cycle of iterative refinement.

“We never treat a product as ‘one and done,’” Rennie says. “From prototyping to production scaling, we’re constantly evaluating how to do things faster, smarter and more cost-effectively.”

Calian also participates in CW’s Top Shops benchmarking survey as a strategic tool. “It’s a great way to identify our position in the composites market as well as any gaps we need to address,” says Rennie. “Are our cycle times competitive? How do our wages compare to industry standards? What markets are others moving into?” According to Rennie, the company uses the survey both to calibrate performance metrics and to assess opportunities for strategic expansion, such as balancing growth between defense and mining or evaluating entry points into aerospace.

One of the more unique aspects of Calian’s composites division is its deep integration between engineering and production. The team’s engineering group includes both design and manufacturing engineers, often working side by side to refine processes during the early stages of a product’s lifecycle.

“We’ve seen a lot of benefit from involving our engineers, technologists and fabricators in our design process to ensure we’re designing with the full manufacturing cycle in mind,” Rennie says.

The division also maintains strong quality control systems, including contact and noncontact laser scanning equipment, as well as in-house environmental and mechanical testing capabilities. This metrology expertise enables precise tracking of tolerances and geometry over time, which is especially critical for parts exposed to thermal cycling or mission-critical deployment conditions.

An eye toward opportunity

Calian Composites is ultimately focused on problem-solving. Rennie says the division sees itself as more than just a composites facility, but as a solutions provider, a systems integrator and a partner that can take you from prototype to full-scale production.

“Whether somebody comes to us with an existing product they are looking to manufacture, or they come with a brand new idea that they want to prototype, we can work with them to define and meet their specific needs,” Rennie says.

This approach has enabled growing the division from a fabricator of SATCOM reflectors to a business with inroads in various markets. And the growth continues; hiring is underway to support increased demand across several product lines.The team is also expanding its R&D efforts to continue bringing new product developments and smart embedded systems to market.

“We are actively hiring a number of positions right now. Specifically, we are bringing on more technologist and fabrication staff to ramp up for the increased work that we have,” Rennie says.

Calian Composites is an example of how strategic focus within a diversified enterprise can drive both resilience and growth. As it continues to scale its operations and explore new frontiers in composite-enabled technologies, Calian is positioning itself not only as a top-performing shop, but as a forward-thinking partner in the evolving composites landscape.