High Volume FRP Production Technology

Innovative High-Volume Production of Composite Leaf Springs

Meeting the demands of future mobility requires lightweight, durable, and cost-efficient structural components. Our innovation focuses on an advanced manufacturing process for composite leaf springs, designed for high-volume production of up to 500,000 parts per year.

By combining resin transfer molding (RTM) technology with optimized tooling concepts, we achieve short cycle times, high reproducibility, and excellent mechanical performance. This one-shot process integrates reinforcement and shaping in a single step, reducing material waste and minimizing downstream operations.

The resulting composite leaf springs deliver:

Up to 60% weight savings compared to conventional steel solutions

Superior fatigue resistance and long service life under dynamic loads

Industrial scalability, making composites a viable solution for large-scale automotive applications

Cost efficiency through automated processing and reduced labor intensity

This innovation bridges the gap between aerospace-grade composite technology and automotive mass production. By adapting high-performance materials and processes to the requirements of series manufacturing, we demonstrate a path toward lightweight suspension systems that are both technically and economically competitive.

With an annual capacity of half a million units, this technology represents a major milestone in composite mass production, supporting the transition to lighter, more efficient, and sustainable vehicles.