What Can IFP Make? A Deep-Dive Into IFP-Components.

‍What Is IFP?

IFP stands for "Infinite Fiber Placement" and is our proprietary robotic production technology that builds components by placing continuous dry fibers (such as carbon or aramid) along digitally optimized load paths.This software-defined approach means we can tailor each component's mechanical properties to exact specifications. See the image below to understand how it works.

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What Parts Can IFP Make?

IFP is optimized for specific types of load-bearing components. Here is what we manufacture:

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1. Load-Bearing Components

IFP-components are designed to carry significant mechanical loads, such as structural parts, industrial hand-held tools, or medical wearables. These are parts that experience tension, compression, bending, or combined loading. We optimize the fiber orientation to reinforce parts as needed.

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2. Flat or Single-Curved Surfaces

We manufacture parts that are either flat or have a single-curvature surface (curved in one direction only). This includes panels, brackets, frames, ribs, and similar structural elements.

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3. Small to Medium-Sized Parts

Component sizes range from a minimum of 100mm x 100mm up to a maximum of 800mm x 800mm (3,9 x 3,9 in up to ~31 x 31 in). This size range covers many industrial applications, from robotic to seat structures.

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4. Carbon and Aramid Fiber Parts

Our default material is dry carbon roving (Tenax IMS65), but we also work with aramid fibers. Glass, natural, and hybrid fibers are available on request.

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5. Thin and Thick Parts

Unlike most composite technologies that focus on either thin or thick parts, IFP handles both, with wall thicknesses from 1 mm to 40 mm (~0.04 x 5.9 in). We can also produce components with varying thicknesses in the same part – something that is difficult with prepreg-based processes.

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Industries and Applications 

While we work with a wide range of industries, IFP-components are well-suited for:

• Industrial Tools: (Parts of) hand-held tools. We replace metal parts with composites to reduce weight.
• Robotics: Robotic (limb)-structures for humanoids and quadrupeds.
• Automotive: Interior structures (seat frames, reinforcements), exterior structures (door components), and structural reinforcements.
• Aerospace: Seat structures, overhead compartments, interior panels, and internal structures for wings and fuselages of fixed-wing UAVs, as well as drone frames for multicopter UAVs.

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If your industry is not listed here, that is not a problem. We focus on load-bearing components for mid- to high-volume production. If you have a component that meets the criteria discussed in this section, we can likely help.

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High-Volume Manufacturing, Not One-Off Parts 

One critical point to understand: IFP is optimized for scalable production volumes, not single prototypes or highly specialized low-volume applications. We start at 50 components/year and scale from there up to 200,000+ parts annually. This focus on volume manufacturing means:

• Lower per-part costs as volumes increase
• Highly repeatable quality through robotic automation
• Simplified tooling that scales cost-effectively
• Fast development from prototype to serial production (weeks vs. months)

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Find the full component specifications here.

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What Makes IFP-Parts Different?

IFP delivers three core advantages at the component level and two at the process level.

Component-Level Advantages

1. Load-Bearing Performance At Reduced Weight

IFP-components allow metal-to-composite transitions achieving up to 70% weight gains and are up to 30% lighter than prepreg alternatives, while maintaining or enhancing the structural performance a part needs.

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IFP-components show visible optimized fiber paths, a distinctive surface finish and visual proof of the engineered performance built into every part.

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2. ESG-Ready: 100% Recyclable And Zero Scrap

• ‍Closed-Loop Recycling: Meet circular economy mandates without compromising performance. Our closed-loop recycling process allows material reuse in equivalent high-performance applications – not downcycled into lower-value products.‍
• Zero Scrap Manufacturing: IFP is a 100% buy-to-fly process (raw material weight/ final part weight.). Using a continuous dry fiber allows us to use only the fiber needed for the part, with no excess material (compared to prepreg-based processes where scrap rates vary between 30-50%).

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3. Advanced Design Features Allow Maximum Design Freedom

Unlike traditional composites that require extensive post-processing, IFP-components integrate advanced features directly during manufacturing, eliminating secondary operations and preserving fiber integrity, and most importantly: maximize your design freedom.

Features we can integrate during manufacturing include:

• Cut-outs and holes 
• Metal transitions
• Adaptive rigidity to adapt a single component design to different load cases or use requirements

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Process-Level Advantages

1. Rapid Development: 12 Weeks from CAD to Production-Ready Prototype

We deliver functional prototypes within 12 weeks that come with a scalable manufacturing concept. This means you can transition directly to serial production without redesign or retooling delays, reducing time-to-market.

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2. Scalable & Flexible: From 50 to 200,000+ Parts

Start small and scale as you grow – no heavy retooling, no supplier switching, no massive capital investment required. Our process adapts to your volume needs, starting with 50 units annually, ramping to 200,000+. This flexibility means:

• Lower risk: Start with small batches to validate performance before committing to high volumes
• Faster scaling: Ramp up production without redesigning tooling or switching suppliers

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Read more about our services here.

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Is IFP A Fit For Your Part?

IFP-components are designed for manufacturers who need load-bearing lightweight parts at scale. Use this checklist to evaluate if IFP fits your requirements. If you checked all component requirements and at least one of the needs below, IFP is likely a strong fit for your application. We offer free part assessments to evaluate your specific requirements.

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Not certain yet? Read our honest technology comparison article, which helps you understand which technology is a fit for which type of part.