Rotocast composite hybrid process for molding composite parts

A method of fabricating a composite part, comprising:

• providing a mold assembly including a tool defining an inner chamber and a cover for sealing an access opening to the inner chamber;
• mounting the mold assembly within a rotocasting machine;
• filling the inner chamber with a volume of a two-part resin that gels, after a gel time has elapsed, when mixed at room temperature;
• after sealing the access opening with the lid, operating the rotocasting machine to cause the volume of resin to uniformly cover surfaces of the inner chamber of the tool;
• and
• after removing the lid and via the access opening, laying up a layer of reinforcing material on an inner surface of the resin covering the surfaces of the inner chamber.

A method for molding a composite, elastomeric product, comprising:

• providing a mold with an access port to an inner chamber;
• filling the inner chamber with a volume of a two-part resin having a predefined gel time;
• coating surfaces of the inner chamber with the two-part resin to define an outer wall of a product with a predefined thickness;
• applying a reinforcing layer to an inner surface of the outer wall via the access port of the mold;
• applying a binding layer over the reinforcing layer attaching the reinforcing layer to the inner surface of the outer wall of the product.