Your World. ®
As a leader in thermoplastic advanced composites,
Fiberforges delivers cost-effective solutions for
manufacturing high-performance products.
Rapid, efficient tape layup equipment
Production of Composite Parts
24,000 sq. ft. production facility
Formed parts up to 1m x 1m
Precision part finishing
Advanced bonding and welding
Ultrasonic non-destructive inspection
Product and process development
Design and prototyping
Partnership with system integrators
With advanced composites, fibers are oriented within
a part so that loads are carried along the fiber direction,
improving performance and minimizing cost. The
Fiberforge process places material only where it is
needed. Thus, scrap and cost are reduced significantly.
All in all, the Fiberforge solution embodies the best
characteristics of advanced composites while
overcoming traditional process limitations.
Fiber-reinforced composites offer significant
advantages over common materials such as
aluminum, titanium or steel. However, the cost to
produce them has traditionally been prohibitive
due to high raw material cost, high scrap rates
and long production times. Enter Fiberforge.
Benefits of thermoplastic advanced composites:
Indefinite shelf life without refrigeration
Low manufacturing costs
Reshaping and reforming flexibility
The Fiberforge Process
Fiberforge’s patented process comprises four automated,
discrete steps: Layup, Consolidation, Forming and Trimming.
Each step takes place rapidly and on a dedicated station,
freeing up the prior station to produce another part and
reducing the total production time to minutes.
The Fiberforge process starts with a state-of-the-art layup machine
that produces tailored blanks.
Tailored blanks are flat multi-ply laminates of unidirectional tape where each
layer of the tape can be rapidly laid up in unique configurations. This allows
such features as complex shapes, many fiber orientations, variable thickness,
and multiple materials to be incorporated into tailored blanks.
After the layup step creates the tailored blanks, then the tailored blanks are
moved on to be rapidly consolidated. Finally, the parts are formed and then
trimmed to their final shape. The Fiberforge patented process fundamentally
changes how composites are produced.
Simply put, the Fiberforge process produces high‐performance
thermoplastic advanced composite parts at higher volumes and
for lower cost than any other competing technology— in minutes.
Click HERE to see the Fiberforge process in action.
� � Tailored Blanks
Fiberforge’s RELAY® Station is an automated
thermoplastic tape layup system. RELAY
stands for “rapid, efficient layup,” and both
the equipment and the process are protected
Fiberforge designs and produces its
RELAY Station equipment and sells to
manufacturers, worldwide to make strong,
lightweight and cost-effective parts.
Fiberforge partners with other equipment
suppliers and system integrators to offer
a complete manufacturing solution.
Fiberforge currently offers the RELAY Stations
in two sizes:
RELAY Station 1000, which can produce
parts up to 1m x 1m in size
RELAY Station 2000, which can produce
parts up to 2m x 2m in size
The RELAY Station utilizes high-speed automation to minimize labor
and improve efficiency. Our proprietary, user-friendly TailorGen
software makes it easy to program the RELAY Station to make custom
unidirectional tailored blanks consistently and rapidly, enabling
engineers to design parts with unprecedented strength and stiffness
to weight ratios.
Production of Composite Parts
Fiberforge produces high-performance composite parts in our AS9100
compliant production facility primarily for the aerospace, defense, and
automotive industries. At our lean manufacturing plant, parts can be produced
up to 1m x 1m in size. We also offer customers advanced joining techniques,
such as induction welding and fusion bonding, and advanced capabilities such
as ultrasonic non-destructive inspection.
Aircraft seat frames, window bezels, secondary structures, and any other parts
with complex contours and variable thicknesses are all possible at Fiberforge.
Demonstrator part produced at Fraunhofer ICT
with the Fiberforge process and Ticona material.
Thermoplastic advanced composites are:
185% tougher than thermoset composites
600% stiffer* than injection-molded plastics
65% lighter than steel
550% stiffer* than steel
40% lighter than aluminum
65% less scrap than sheet goods
* specific modulus
“We are extremely happy with the
Fiberforge parts. Not only are they
significantly lighter weight and more
functional for our customers, but
they are actually more cost
competitive and have saved us
significant labor expense.”
— Dana Gleason,
founder and president of Mystery Ranch
In partnership with Ticona
and Oxeon Inc., this automotive
underbody shield was produced
at Fraunhofer ICT using the
Fiberforge process and
over-injection molding process.
“Fiberforge’s innovative tape layup
process opens new possibilities for
producing thermoplastic advanced
composite parts in a fast and robust
process for large-scale manufacturing,
and in combination with other
technologies such as compression and
injection molding. The Fiberforge Relay
Station is key to these developments
and will expand our research and
development portfolio of methods,
materials and process technologies for
— Dr. Ing. Frank Henning,
Deputy Director of Fraunhofer ICT
Working with Fiberforge
Fiberforge is a global company with customers in the U.S., Europe and Asia.
As experts in thermoplastic advanced composites, our goal is to help our customers
move rapidly through the development process and emerge with winning products.
We offer manufacturing equipment and production of composite parts in our AS9100
compliant manufacturing facility. Fiberforge’s manufacturing equipment can produce
composite parts up to 2m x 2m in size.
Fiberforge’s advanced composite team is one of the most experienced in the world,
having designed and launched products ranging from life-saving military protective
equipment to performance-critical aerospace systems. No other company in the
industry has the level of thermoplastic expertise, design experience, process
knowledge and production capability.
Fiberforge is a partner with you—whether you choose to implement the Fiberforge
process at your facility or ours.
1420 Devereux Road
Glenwood Springs, Colorado
phone +1.877.945.9377 | +1.970.945.9377
Mattweg 3, CH-6340 Baar, Switzerland
phone +41 (0) 188.8.131.52
Contact Fiberforge to discuss
how we can help you innovate
We understand our customers’
needs. We operate globally. And
we always enjoy a challenge.
Fiberforge’s technology is protected by
U.S. patents 6,607,626; 6,939,423; 7,235,149;
8,007,894; 8,048,253 and patents pending.
© 2012, Fiberforge Corporation.