OEM and Tier 1 partner for composite components and assemblies across the entire product life cycle. From consulting in the design phase through engineering and series production to spare parts and long-term service.

  • 01

    Consulting

    Your partner for composite decisions throughout your entire product strategy. We bring in-depth material expertise and over 50 years of manufacturing experience to ensure the advantage of composite is used to improve the product performance while optimizing for lifecycle costs.

    Input on product design and material selection. We identify functions that can be integrated into the composite. The goal is the lowest TCO over the lifecycle. Not the lowest unit price.

    Assessment of the design for reproducibility (DfM). Recommendation on sandwich versus single skin. Identification of critical zones.

    Selection of material systems for EN 45545-2 (up to HL3) and NFPA 130. Based on established and prevalidated systems.

    Joint development of modernization and retrofit concepts for fleets and platforms. From mobile service concepts to lifecycle extensions.

  • 02

    Design & Engineering

    As a system partner we take full responsibility for the development and validation of the composite assembly. You deliver the industrial design. We engineer. We calculate. We validate. We ensure the serial production readiness.

    Both systems are in productive use. They are compatible with the workflows of leading international OEMs and Tier 1 suppliers.

    Design and development of all components and add-on parts. Integrated functions such as emergency exits, kinematics, interchangeable frames, lighting and electrical and pneumatic subsystems. Complete technical documentation including manufacturing drawings.

    Structural integrity is validated in the digital phase. It feeds directly into development.

    The production sequence is considered during the design phase. This enables stable and cost-efficient series production with no surprises later.

    Coordination of the EN 45545-2 and NFPA 130 tests in accredited labs. Based on established and prevalidated material systems.

    Our own material tests for GRP, adhesives, paint systems and electrical, hydraulic and pneumatic components. Supplemented by accredited partner labs where needed.

  • 03

    Tooling & Industrialization

    An in-house center of excellence. Drawing on decades of experience we define the optimal tooling for your project. It is matched to time-to-market, lifecycle and output rate during ramp-up. From the CAD dataset we create the production-ready tool or a fast prototype. We also create the process behind it. That process enables a stable series.

    For the production of models, molds, gauges and other production aids.

    We build prototypes from the original material in the shortest possible time. These are not 3D printed MVPs. They are meaningful samples for function and bonding tests.

    This secures the dimensional accuracy of tool and component before the first part is made.

    Paint templates, bonding gauges and assembly aids secure consistent execution quality across the entire series.

    We deliver more than the tool. We deliver the matching production process. Material handling. Curing windows (tempering). Bonding specification. Paint build-up. Inspection protocols. This way the series runs stable from day one.

    A milestone carried out together with you. A transparent transition from industrialization into series production.

  • 04

    Series Production & Assembly of Components

    Scalable composite series production from a single piece to fully assembled and painted series production. With documented quality and delivery flexibility that fits your ramp-up.

    Hand lamination for complex components and high viscosity fire protection systems. Vacuum infusion and RTM Light for a precise resin-to-glass ratio, lightweight construction and repeatability. Press processes for high-volume painted series components.

    Bonding to DIN EN 17460. Up to safety class A1 when required. Internal bonding supervision (vKAP) and audited in-house procedures. Bonding of windshields and safety-critical joints with full traceability.

    Including purchased welded structures to EN 15085, electrical and electronic pre-assembly and the integration of hydraulic and pneumatic components.

    Our own paint facilities handle three-layer exterior coating through to structural paint for interior panels. No external interface. No hidden supply bottleneck.

    Standard delivery is on time into your buffer warehouse. For time-critical projects we deliver just-in-sequence directly to your assembly hall. You rely on assemblies that arrive pre-assembled, inspected and within tight tolerances. With GRP that is not a given.

  • 05

    Service

    Composite assemblies live 25 to 30 years. So do we. From the first incident on a vehicle to spare parts supply long after end of series, one contact person stands by you across the entire lifecycle.

    We design and deliver lifecycle extensions for entire fleets. From damage assessment through the engineering solution to implementation.

    Evaluation of damage patterns. Preparation of damage reports. Recommendations on repair or replacement. Support in negotiations with third parties such as insurers.

    A multilingual and well-coordinated repair team with tools, material and lamination expertise directly in your depot or maintenance facility. For maximum availability of your vehicles.

    Laminate build-up, surface finish and paint bonding are fully documented and traceable. Repair on the vehicle or in a disassembled state. It depends on the damage pattern.

    Short response times. Reliable feasibility assessment. Implementation within agreed deadlines. Windshield example: replacement at the maintenance facility in two hours with our interchangeable frame system.

    Delivery directly from the original tool. Or on a reengineering basis when the tools are no longer available.

    Planning of maintenance measures within the vehicle lifecycle (RAM/LCC).

    So your workshop staff can work independently at a consistent quality level.

    Documented and traceable throughout. We are also happy to advise on third party products or on the purchase of GRP components.