Composite Assemblies for Railway: Rolling Stock

Partner from development and series production through to lifecycle management for OEMs and Tier 1 suppliers

Certified. Tested. Ready for production.

GRP system assemblies for rail vehicles from the market leader

Composite and glass reinforced plastic (GRP) components are ubiquitous in modern rail vehicles. These materials and manufacturing processes enable the production of a wide range of components, from large-scale, structurally load-bearing front assemblies and exterior panels—extending from the bogie to the roof—to interior components that meet the most stringent requirements for fire safety and ease of maintenance.
The range of materials and processes offers the optimal combination of durability, mechanical strength, design flexibility for industrial applications, serviceability, and low total cost of ownership (TCO) over the entire lifecycle.

With over 200 projects in the rail vehicle industry, we have a thorough understanding of the requirements:

Efficient project management and product design optimized for series production (manufacturing of components, assembly of subassemblies in the vehicle, consistent quality)
Reliable delivery straight to your assembly line
The choice of materials must stand the test of time: they must be reliable for many years, even in situations that have not yet been defined. The safety of passengers and staff, and the durability of components in extreme situations, are non-negotiable
A 20-year lifecycle with no downtime

Why Faserplast

Strategic system partner with full responsibility

We are dedicated to being the composite partner that ensures the success of your project. This allows you to focus on developing innovative, high-quality products and an efficient assembly line.
We don’t just supply composite shells; we develop, manufacture, and assemble complete front assemblies – complete with integrated kinematics, (emergency) exit doors, windshield replacement frames, aprons, spoilers, and lighting. We are actively reducing your project complexity and interfaces.
Our strength lies in guiding you through every stage of the process, from concept to series production. Whether you’re planning to produce a prototype in three months, a pre-production run in ten months, or ramp up to series production in twelve months.

We help develop the product – not just follow the blueprints

Consistent project management and development from order placement through to series production. With our experience and expertise, we ensure the success of your project. Streamlining interfaces reduces your project workload and risk – whether for individual parts or entire assemblies.

Material selection optimized for your application

Composites and glass reinforced plastics (GRP) are a field of materials science. There is no single material system or layer configuration that works in every situation. We are the market leader (and leader in expertise) at the intersection that matters most to you: material systems – manufacturing processes – specific applications. The proof: zero in-service failures across around 3,000 front cabs. We conduct research and development that directly informs your products.

Reliable composite plug-and-play assemblies

A reliable partner for painted and assembled system modules, delivered ready for the rail vehicle assembly line, thereby reducing your workload and minimizing disruption to your planning, so you can focus on ramping up final assembly.

In-house expertise and capacity

We integrate project management, development, tooling, and prototyping with the series production of your products as painted system assemblies, ensuring your project’s success. With three locations and over 20,000 square meters of production space, we have the capacity to scale with you.

Measurable. Not just a promise.

Where the benefit lies

20 – 60 %

less weight

Our innovative design enables a weight reduction of up to 20% compared to conventional GRP suppliers and up to 60% compared to traditional welded steel structures.

-25 %

as a percentage of total project costs (NRC)

Our integrated project management reduces the coordination effort for your team, giving your experts more time to focus on your products.

-50 %

in lifecycle costs

By using the right combination of materials and manufacturing processes to prevent future repairs to GRP.

In series production since 1972

Composite assemblies for rail vehicles, from small-batch to high-volume production

Front assemblies

Structurally load-bearing front cabs with no compromise on weight, mechanical strength, fire protection, or design.

Driver’s cabs & driver’s desks

Functional desks and trim parts optimized for efficient installation and maintenance.

Exterior trim parts

Aerodynamic and design-defining exterior components for OEMs and Tier 1, such as aprons, spoilers, lamp housings, or exchangeable frames for windshields.

Interior trim parts

Entrance and stairway paneling in the passenger compartment, ducts and covers for ventilation and heating.

In series production since 1972

We stand for the optimal product and your project success, built on our experience and expertise.

Strategic system partner to internationally leading rail OEMs and Tier 1 suppliers. Our composite assemblies for metros, intercity, and high-speed trains are in service on four continents.

~3,000

Front cabs delivered

50+

Years of composite experience

Global

Presence for service

3 locations

Switzerland · Poland · USA

Lightweight Construction with Infusion Components
Series production of structurally highly loaded large components for rail vehicles with maximum lightweight requirements to reduce energy consumption and axle loads.

EN 17460 A3EN 15085EN 45545-2 HL2
Replacement Cabs for Service Life Extension (Refit)
Design and manufacture of a precisely fitting front cab for the mid-life upgrade of existing double-deck trains.

EN 45545-2 HL2EN 17460 A1
Front Cab with Integrated Emergency Exit Door
Development and manufacture of a front cab with an integrated emergency exit door, an exchangeable frame system for the windshield, plus aprons.

EN 15085NFPA 130

All References

FAQ

Frequently asked questions
from purchasing and engineering

How does Faserplast support RAM/LCC analyses?

We provide RAM/LCC-relevant data for tender submission: documented failure rates from series production, availability concepts (e.g., windshield exchangeable frames with a two-hour replacement time), maintainability specifications, and LCC models for composite assemblies across the vehicle’s service life.

Do you also offer standalone repairs?

With our team of experts, we are happy to inspect your vehicles / assemblies — whether in the depot or still on the assembly line. Based on the situation, we then offer rapid spare parts or an on-site composite repair — so the vehicle stays in circulation or the assembly line doesn’t come to a standstill.

Do you also offer build-to-print?

Yes, in principle we also support our customers with individual parts and build-to-print projects. Our expertise in material selection and our commitment to quality in production ensure that here, too, you receive the optimal product.

Which locations are relevant for Buy America or local content requirements?

Faserplast manufactures in Switzerland, Poland, and the USA. Depending on the platform and contract region, value creation takes place at the appropriate location.

At what quantity does a composite front cab become economical?

Typically from 30–40 vehicles per platform — the standard range for modern rail platforms. Engineering and tooling costs are amortized across the series. The advantages in weight, design freedom, and integration remain throughout the lifecycle.

Which fire protection standards do Faserplast composites meet for rail vehicles?

EN 45545-2 up to HL3 and NFPA 130. Material selection, laminate structure, and testing procedures are coordinated early in the design phase and adapted to the product and application.

How does collaboration work during the development phase?

We serve every project with an experienced project manager and project engineer who support our customers from concept to series production. The project manager is responsible for the entire development process, ensures that your requirement specification is met, and that an economically and technically optimal solution is created. We handle design, calculation, tool making, and first article production. Load cases are validated, and after a jointly conducted first article inspection, the assembly is delivered to your final assembly as a plug-and-play module. The project manager also serves as a sparring partner for the interfaces and is happy to take over coordination with your third-party suppliers directly.

What distinguishes a composite system supplier from a pure GRP manufacturer?

As a composite system supplier, we don’t simply produce trim parts – we are a preferred partner for complete assemblies, across the entire lifecycle.

What does partnership on equal footing mean?

Our goal is your project success. As a partner on equal footing, we see our role as bringing your project to success with composite solutions — technically, economically, and on schedule. You provide the industrial design, and we develop the assemblies. As a system supplier, we reduce interfaces and risk — because we ensure the fit through our assembly.

Discuss your project with our experts

Talk to an expert

Railway: Rolling Stock

Construction Machinery & Cranes

Special Purpose Vehicles (SPV)