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Through the development and implementation of fibionic fiber placement (FFP), (Götzens, Austria) is able to achieve bionic-optimized semi-finished products called “fiber skeletons.” Suitable for any application, they boost performance, advance fiber placement and achieve zero waste at high volumes using a variety of reinforcement and matrix options.

Mimicking nature, FFP uses composite reinforcement exactly where it is needed, enabling 30-60% weight savings in parts and 20-40% material savings. Fibionic’s preform process begins with CAD and digital optimization, followed by fiber alignment using its patented air stream FFP technology. 2D stacks are then consolidated and transformed into 3D preforms in a final thermoforming step, ready for subsequent integration into high-performance parts like the Saddle Skeleton shown here.

The fiber skeleton (left) is the load-bearing structure of a bike saddle (right). It comprises carbon fiber-reinforced PA12 with ~52% fiber content by volume, which is then integrated with injection molded short carbon-reinforced PA12 to enable a fully recyclable thermoplastic composite saddle at a production output of one part per minute. Using the FFP process optimized the structure’s fiber angles and material distribution, achieving a product that can save 25% weight compared to a pure injection molded counterpart, or match the properties of saddles made with carbon fiber prepreg.