Written by Kerryn Caulfield, Executive Director, Composites Australia Inc.
The Bolwell marque is an acknowledged legend in the Australian automobile industry as much for the advanced composites used in its construction, as for its unique design features of its legacy performance-driven classic cars. Initially celebrated for its innovative cars, notably the Nagari sports car – that brothers Campbell and Graeme Bolwell produced from 1962 – Bolwell equally pioneered the production of fibreglass parts and components for heavy transport.
he foundation of Bolwell’s success lies in its early recognition of unique properties and qualities of composite materials, not just as an alternative to metal. Years of design, trials, testing, investment and experimentation enabled the company to pioneer advanced design solutions which led to the wider acceptance and use of polymeric materials. Members of the founding Bolwell team are now rightly recognised as some of the industry’s founding innovators.
“We are tremendously proud of the contributions Bolwell has made to the K220. It is an exceptional truck, a testament to Australian design, engineering, and manufacturing, and the Truck of the Year award is recognition of this,” CEO Vaughan Bolwell
The partnership with heavy transport companies, particularly Kenworth and Iveco, dates back to the early 1980s. The relationship began serendipitously after a Kenworth executive’s encounter with the Bolwell Ikara, a kit car designed by founder Campbell Bolwell in 1978 and marketed as a ‘highly affordable true sports car’.
International firm PACCAR established a manufacturing facility in Bayswater, Melbourne, in 1970 for Kenworth truck production. Impressed by the Ikara, Bolwell was then approached to fabricate the bonnets.
Together they transformed the manufacture of legacy components, including the hoods using composite technologies which reduced weight at the front of the vehicle and improved handling as well as fuel efficiency.
Since those early days, Bolwell has grown into the largest manufacturer and supplier of composite parts to the Australian heavy transport industry, producing a range including hoods, roofs, fairings, guards and dashes. Recent highlights include a significant engineering, validation and production support for the Kenworth K220, which was awarded 2023 Truck of the Year Australia.
Investment in technologies, systems, standards and accreditations is a prerequisite for acceptance in the automotive and heavy transport sectors.
Bolwell expanded its credentials beyond ISO 9001:2015 by embracing environmental best practices and securing ISO 14001:2015 accreditation. Vaughan explains, “Our move to ISO 14001 accreditation stemmed from the need to manage challenging raw materials and meet rising expectations from international clients. The ISO framework has enhanced our environmental performance ensuring better process control, more efficient resource use and reduced waste, and is a true commitment to our sustainability obligations.”
Continuous improvement also informed the adoption of Lean Manufacturing principles, particularly the Toyota Production System (TPS). The company utilises Kanban to schedule work throughout its facilities for visible and efficient order tracking, along with Kaizen activities to review and optimise processes and systems.
Bolwell’s expertise in creating moulds allows for the intricate shapes and sizes of truck and trailer parts to be replicated with exacting accuracy, ensuring a perfect fit and optimal performance. Parts are made using a range of composite techniques, from open moulding to silicon bag closed moulding, and bespoke RTM-Lite system (Resin Transfer Moulding-Lite) optimised for efficiency and control over the resin content and distribution. The closed moulding process minimises emissions during production by ensuring precise resin application and lowering material waste