Round tubes25–150 mm outside diameter in several wall thicknesses.F1-FORM· Custom profiles
Custom pultruded profiles, engineered to your specification
Cross-sections up to 600 × 300 mm and walls from 1.5 mm, in E-glass, carbon, basalt or aramid fiber with polyester, vinyl ester, epoxy or polyurethane resin. Each profile gets its own die, a trial run and test data before series production.
FIG. 1 From section drawing to profile
What we can pultrude
The dimensional range of the production lines, then the four material choices that define a profile, from the fiber core out to the finish.
Dimensional range
Limits of the current lines; other lengths on request. A section near a limit is still worth sending: the feasibility review says what would have to change.
| Dimension | Range |
|---|---|
| Maximum cross-section | 600 × 300 mm |
| Minimum wall thickness | 1.5 mm |
| Maximum wall thickness | 30 mm |
| Maximum profile length | 14 m standard |
| Dimensional tolerance | ±0.25 mm typical |
Material matrix
Layer 1
Fiber
- E-glass
- The standard choice, with the best strength for the cost.
- Carbon
- Much higher stiffness and strength.
- Basalt
- Better heat and chemical resistance.
- Carbon-glass hybrid
- Balances stiffness, weight and cost.
Layer 2
Resin
- Unsaturated polyester
- Cost-effective for general service.
- Vinyl ester
- For chemical exposure.
- Epoxy
- Highest mechanical performance.
- Polyurethane
- High toughness and transverse strength.
Layer 3
Surface reinforcement
- Glass surface veil
- A smooth, resin-rich surface that shields the fibers from UV and corrosion.
- Woven glass fabric
- Multi-axial strength and impact resistance.
- Combination mat
- Roving and chopped strand mat in one ply for balanced properties.
- Carbon fiber mat
- A conductive surface for EMI shielding.
Layer 4
Coating and finish
- Fluorocarbon (PVDF)
- The most weather-resistant coating; performance follows the coating system's data.
- Powder coating
- A durable color finish in RAL colors.
- Film lamination
- Wood grain, marble or a custom pattern.
- No coating
- UV-stabilized resin and surface veil, without a paint layer.
Check the existing dies first
FengDu's production network holds 1,000+ die sets. A variant on an existing die (another resin, color or length) takes 4–6 weeks; a new die takes 6–10 weeks from approved drawing to first delivery. These families already run:
- Round tubes25–150 mm outside diameter in several wall thicknesses.
Square and rectangular tubesSquare and rectangular hollow sections with nominal walls and weights.
Flat sheetsSolid sheet cut to size, with smooth, gritted or embossed surfaces.
Hollow and multi-cell platesPlate profiles with enclosed cells, drawn from the section catalog.
Window and door profilesFrame, sash, mullion and sill sections for fabricators.
Supplier photoWind turbine blade panelsGFRP, CFRP and hybrid panels cut to the project length.
Sound barrier wall panelsPanel systems for highways, railways and industrial sites.
Plant and tree stakes5–19 mm rods for vineyards, nurseries and plantations.
I-beams, channels, angles, rods and flat bars are in the standard structural shapes; every family is listed under product lines.
From inquiry to series production
About 6–10 weeks from an approved drawing to the first delivery. The die is the longest step.
Step 11–3 days
Inquiry and feasibility
Share your geometry, loads and environment. We assess whether the section can be pultruded and propose changes that help it run.
Step 25–10 days
Engineering and simulation
Fiber architecture, FEA checks, resin selection and the quality plan for the section.
Step 34–8 weeks
Tooling manufacture
CNC-machined steel dies, guide plates and preformers, designed and built in-house.
Step 41–2 weeks
Trial and validation
A production-grade trial run with mechanical testing. You approve the profile before production starts.
Step 5Ongoing
Production and delivery
Series production with batch testing and certificates on request. The die is stored for repeat orders.
How the line itself works (creel, resin bath, heated die and puller) is explained in the pultrusion process guide.
What custom pultrusions cost
Every program has two cost components: a one-time die and a price per meter.
One-time
Tooling
- Single-cavity die, small open profile
- USD 5,000–8,000
- Large or multi-cavity die
- USD 15,000–40,000
The die stays at our plant, maintained at our cost, for the life of your product. On a typical production run the amortized tooling share of the per-meter price becomes negligible within the first order.
Per meter
Profile price
Driven by the same factors as any pultruded shape: cross-section area (glass and resin mass per meter), resin system, fiber architecture, surface veil and order volume. First production runs start at 500 linear meters; repeat orders from 200 meters.
For a directional number before you commit to tooling, run the closest standard shape through the pultruded profile price estimator, then add the tooling line from the ranges beside it.
Custom pultrusion questions
How much does custom pultrusion tooling cost?
Tooling costs depend on the complexity and size of the cross-section. Simple single-cavity dies for small profiles start at approximately USD 5,000–8,000, while large or complex multi-cavity dies can range from USD 15,000–40,000. Tooling is a one-time investment that we maintain and store at our facility for the life of the product. For high-volume programs, the tooling cost per linear meter becomes negligible within the first production run.
What is the minimum order quantity for custom profiles?
The minimum order quantity for a first production run is typically 500 linear meters, which is the minimum length required to validate process parameters and ensure consistent quality across the batch. Repeat orders can be as low as 200 linear meters. For prototype or development quantities below these thresholds, we offer trial run packages that include a limited quantity of validated profile along with full mechanical test data.
Can you match an existing steel or aluminum cross-section?
Yes. We routinely design pultruded FRP profiles as direct replacements for steel and aluminum sections. However, a direct dimensional copy is rarely the optimal approach. Because FRP has different mechanical properties than metals, particularly a lower elastic modulus, we typically recommend modifications to the cross-section geometry such as increased moment of inertia, thicker flanges, or additional internal stiffening ribs that optimize the profile for FRP-specific behavior while maintaining the same connection and envelope dimensions.
What lead time should we expect from inquiry to first delivery?
For a new custom profile with no existing tooling, the typical lead time from approved design to first delivery is 6–10 weeks. This includes tooling manufacture (4–8 weeks), trial run and validation (1–2 weeks), and production of the first order (1–2 weeks). We can compress this timeline for urgent projects by running parallel workstreams, though expedited fees may apply. Repeat orders with existing tooling typically ship within 2–4 weeks.
Send your custom profile requirements
Start with a drawing or a sketch. We review feasibility and propose changes that help the section run, then quote the die and the per-meter price together. We reply within one business day; a formal quotation follows once the specification and delivery are reviewed.
- Section drawing
- A DWG, DXF, STEP or PDF of the cross-section, or a sketch with the critical dimensions and tolerances.
- Loads and service
- Spans and loads, the environment (chemicals, UV, temperature) and any fire or electrical requirement.
- Material and finish
- Preferred fiber, resin, surface and color, or the performance you need so we can propose them.
- Quantities and delivery
- Cut length, first-run and annual quantity (first runs from 500 m), destination and target date.