Fiberforge installs the largest RELAY Station in the world at Fraunhofer ICT

Nov 10 2011


GLENWOOD SPRINGS, Colo., 7 November 2011 — Marking a milestone in the company’s global reach, Fiberforge has successfully installed its first RELAY® Station in Europe – the RELAY Station 2000 at Fraunhofer Institute for Chemical Technology in Pfinztal, Germany.

Fraunhofer ICT will use Fiberforge’s RELAY Station 2000 – the largest in the world – at its state-of-the-art thermoplastics research center to conduct R&D projects for various industries including automotive and aerospace. The RELAY Station 2000 offers clients the ability to develop and demonstrate the production of thermoplastic advanced composite structures upward of 2 m x 2 m (80 in. x 80 in.) on a full-scale production work cell.
The RELAY (Rapid, Efficient Layup) Station creates tailored multi-ply preforms from unidirectional thermoplastic prepreg tape that can then be formed into a final part. Unidirectional tape combines a reinforcing fiber, such as glass and carbon fiber, with thermoplastic resin types, such as Polypropylene, Polyamide or PEEK. Tailored Blanks™ can be made with varying thickness and fiber orientation to maximize structural performance. The automated RELAY Station reduces the labor intensity of advanced composite part manufacturing, thus expanding the commercial reach of these materials into higher-volume markets and products. Tailored blanks also can be incorporated into injection and compression-molded parts as inserts for improved strength and cost efficiency.

“Fiberforge’s innovative tape layup process opens up new possibilities for producing thermoplastic advanced composite parts in a fast and automated process,” says. Dr.-Ing. Frank Henning, Deputy Director of Fraunhofer ICT. “Combined with our expertise in other thermoplastic processing technologies, Fiberforge’s RELAY Station will expand our portfolio in the research and development of methods, materials and process technologies for fiber-reinforced plastics.”

Dr. Simon Jespersen, Director of Fiberforge GmbH, says “making the RELAY 2000 technology available at the ICT gives the industry an unforeseen degree of possibilities for using tailoring local reinforcements even in high production volumes. The Relay Station 2000 is state-of-the-art equipment which delivers unprecedented precision, speed and flexibility for a wide range of applications.”

About Fraunhofer ICT
Fraunhofer ICT scientists carry out research and development work in the business areas of defense and security, air and space travel, automotive and transport technology, chemistry and process engineering, energy and environment. Fraunhofer ICT is one of the institutes that currently make up the Fraunhofer Society. Beside contract research for industry, the Fraunhofer ICT also works closely with commercial companies, often through research projects co-financed by the German government or the European Union.

About Fiberforge
Fiberforge is a leading‐edge manufacturing technology company that has developed a patented process for cost-effectively producing lightweight structural parts made from high‐performance advanced‐composite materials. Fiberforge sells turnkey manufacturing systems to part producers across several industries worldwide, including aerospace, defense, consumer electronics, transportation and medicals. Fiberforge also manufactures parts with its technology, primarily for aerospace and defense applications. Fiberforge’s products are protected by U.S. and international patents and patents pending. Visit for more information.

The projections and forward-looking statements in this release are based on best practice analysis and research from independent advisors to Fiberforge. The conclusions drawn, while the result of the best efforts of the staff of Fiberforge, are in no way a promise of delivery, and can, and will, be changed according to future input. For further information, please contact Simon Jespersen ( at Fiberforge and Benjamin Hangs ( at Fraunhofer ICT.

< Return to News & Events