custom fiberglass pultrusion

What's Pultrusion?

What’s Pultrusion? 

Pultrusion is a manufacturing process for converting reinforced fibers and liquid resin into a fiber-reinforced plastic, also known as fiber-reinforced polymer (FRP).  

The pultrusion process allows continuous production of FRP structural shapes in an automated, energy-efficient process by pulling fiberglass rovings through a resin bath or resin impregnator that completely saturate the reinforcements. The resin hardens from the heated steel pultrusion die, resulting in a strong, lightweight final product that follows the shape of the die.

tencom pultrusion process

Pultrusion Process

Pultrusion machine design can vary as part geometry can differ. The two main types of pulling systems used to create FRP profiles are reciprocating (hand-over-hand) and continuous (cat-track).

The rovings of fiber reinforcements are positioned by the creels for continuous feeding onto the guide plate. To ensure strength and quality, the fiber reinforcements must be positioned accurately within the finished composite.

The resin impregnator is optimally designed to completely saturate the fiber reinforcements in a resin bath or wet out that consists of either epoxy, polyurethane,  polyester or vinyl ester. Fillers and other additives such as colors, fire inhibitors and UV retardants can be included to improve the lasting performance of the composite.  

As the reinforcements exit the resin impregnator, they’re passed through “pre former” tools, designed to squeeze out surplus resin and organize the fiber reinforcements into the correct shape. During this process, additives such as continuous strand materials and protective surface veils are often included to improve the structure, resistance to corrosion and finish of the final product. 

After this process, the resin impregnated fiber passes through the steel die for polymerization. The die is heated at a consistent temperature to cure the thermosetting resin, resulting in a solidified polymer.            

 The hardened FRP is then pulled towards the saw by the pulling system for accurate cutting to the desired length. The pull locks are custom made of urethane to ensure cured profiles aren’t cracked, distorted or deformed by the pulling system. 

pultrusion capabilities guide

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Custom Fiberglass Pultrusion Capabilities

Fiberglass Reinforced Pultrusions Custom Pultrusions
Materials Fiberglass Composite
Fiber Type E-Glass
E-Glass & Mat
Resin Systems Standard
Components Resin
High Strength
Superior Dimensional Stability
Electrical Insulation
Thermal Insulation
Corrosion Resistance
Electromagnetic Transparency
Consistent Cross Section
Inherent Color
Part Consolidation
Ease of Fabrication and Installation
Colors White
Shapes Solid Rods
Conductor Rods
Custom Profiles
Bar Stock (Rectangle & Square)
Oval Solids
Half Rounds
Almost Any Profile
Process Roving
Mat / Roving
Resin Bath
Heated Die
In-Die Heat Cure
Cut to Length
Width Up to 15 in
Height Up to 6 in
Tolerance .005 in
Additional Services Drilling
Sand Blasting
Production Volume Prototype to Large Scale Production
Lead Time 3 to 4 weeks

Additional Information

Industry Focus Electrical
Recreation Sporting Goods
Intended Applications Plant and Tree Stakes
Duct Rod
Transformer Spacers
Isolation Rods
Cable Support Rod
Corrosion Resistant Equipment
Food Processing Machines
Tent Poles
ATV Whips
Soccer Poles
Window Shades
Flag Poles
Driveway Markers
Retaining Wall Pins
Advertising Panels
Industry Standards ASTM
File Formats AutoCAD