Bespoke FRP Profiles Engineered to Your Specification

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 to 8,000, while large or complex multi-cavity dies can range from USD 15,000 to 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.

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.

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.

For a new custom profile with no existing tooling, the typical lead time from approved design to first delivery is 6 to 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 to 4 weeks.