Written by Kerryn Caulfield, executive Director, Composites Australia Inc
“What defines RPC is its engineering culture,” says Managing Director Tony Caristo. “We operate across multiple boundaries/entities and countries as One RPC, a strategic initiative designed to integrate our engineering, manufacturing and operations, standardise our processes, and enhance collaboration across our group to tackle complex composite engineering challenges in water, wastewater, defence, transport, and asset services. and infrastructure sectors. By consolidating our expertise, technologies, and capabilities into a single cohesive framework we provide more efficient, consistent, and innovative solutions to meet the evolving needs of our customers.”
For more than 50 years, RPC Technologies has built its reputation on this culture. The company brings together multidisciplinary teams of engineers, material scientists and specialists across its facilities in Australia (Newcastle, Geelong), Indonesia and India, applying composites expertise in glass reinforced plastic (GRP), glass reinforced epoxy (GRE) and carbon fibre reinforced polymer (CFRP) to projects in defence, transport, mining, and civil infrastructure.
DEFENCE CAPABILITY
Among RPC’s long-standing defence programs are the acoustic windows for the Collins Class submarines and the sonar domes for both Collins submarines and ANZAC frigates. These precision-engineered composite laminates house and protect sensitive sonar equipment, allowing acoustic energy to pass through with minimal distortion—a property known as acoustic transparency. The structures deliver the strength and durability required for decades of naval service, while reducing weight and extending service life compared with metallic alternatives.
With the Collins Class fleet now scheduled to remain in service into the 2040s, RPC will continue to support the fleet, including re-engineering, repair, and replacement of acoustic windows and ANZAC sonar domes. The program involved extensive R&D into new materials, construction techniques and validation processes to meet evolving naval requirements, underscoring the role of engineered composites in acoustic signature control — a defining factor in the survivability and operational effectiveness of Australia’s maritime force. Sea capability also includes sustainment and specialty composite parts for LHD, yardarms, flag bins and handrails.
RPC also contributes to composite components for Land platforms including the Bushmaster and Hawkei vehicles, manufacturing ballistic protection systems, dashboards and lightweight assemblies where composites reduce mass without compromising safety or durability.
TRANSPORT AND SAFETY
RPC manufactures interior and exterior systems for Australia’s major passenger rolling stock fleets, including Waratah, OSCAR, Millennium, X’trapolis 1, VLocity, Sydney Metro, Melbourne’s E-Class trams and currently the Perth MetroNet, NGT and Xtrapolis 2. Products range from seating, toilet modules and wall panels to driver cabs, train fronts and ballistic-rated cab masks. Each design is validated against stringent fire and impact standards, ensuring reliability and safety in operation.
The company’s expertise in fire performance standards — from BS 6853 to the current EN 45545 framework — has positioned it as a trusted supplier of fire-rated composites for the rolling stock industry.
By combining materials science, mechanical engineering, and compliance expertise, RPC has expanded the use of lightweight composites in public transportation while maintaining passenger comfort and safety as top priorities.
Engineering Leadership – Virginie Murphy – Engineering Manager
Based at RPC’s Broadmeadow facility, Virginie Murphy leads programs across rolling stock, mining and defence. Her qualifications span a Materials Engineering degree from Polytech Montpellier, a Master’s in Advanced Materials Science from Cranfield University, and a Master of Engineering Management from the University of Newcastle.
The team manufactures composite components for passenger rolling stock, from interiors to safety-critical structures such as cab fronts. Murphy is also instrumental in continuing the innovation of carbon fibre mine vent ducting and corrosion-resistant Permaglass pump columns for deep-well water extraction. Her role in finite element analyses of electrical enclosures for Ampcontrol illustrates how RPC applies advanced simulation to enhance structural integrity in demanding environments.
Murphy has also guided Defence programs through materials obsolescence, verification and tooling development. Her contributions have been recognised with the Hunter Manufacturing Awards’ Rising Star Award and the title of 2024 Engineer of the Year.
Engineering Leadership – Simon Karpeles – Head of Engineering
Since joining RPC in 1990, Simon Karpeles has led multidisciplinary teams delivering major infrastructure and defence projects. Trained as a civil engineer with a background in materials science, he combines laboratory analysis with applied engineering across mining, chemical processing, power generation, marine, wastewater and defence.
His teams specialises in advanced composite fabrication methods — including filament winding, resin transfer moulding, and vacuum consolidation — using glass, carbon, and aramid reinforcements. Under his direction, RPC has delivered Australia’s largest GRP vessels and stacks, turnkey cooling water systems for power plants across the Asia-Pacific, major odour control facilities, and landmark civil works, including GRP risers for desalination plants and deep maintenance shaft structural liners for New Zealand’s Central Interceptor project. His leadership in applying Australian, US, British, and international standards has ensured that these assets meet the highest benchmarks for strength, durability, and corrosion resistance.
Karpeles holds a Bachelor of Civil Engineering (Hons) and is a Registered Professional Engineer of Queensland (RPEQ), as well as a member of Engineers Australia. He was named 2025 Engineer of the Year in recognition of his leadership in advancing composite infrastructure and defence capability.
Virginie Murphy and Simon Karpeles represent RPC’s engineering depth, but their achievements are part of a collective effort. They work alongside other senior specialists, such as Technical Services Manager Leigh Spencer, who has overseen materials R&D, laboratory development, and the mentoring of engineering staff for more than two decades. Around 30 per cent of RPC’s workforce holds an engineering degree, reflecting the company’s ethos. Together, this capability strengthens Australia’s sovereign industrial base and has driven RPC’s adoption of advanced composite manufacturing methods improving both the efficiency and scalability of production.
