Custom FRP Manufacturing: Your Spec, Our Production Line
Off-the-shelf FRP products cover many applications, but engineered projects often require custom cross-sections, resin systems, or mechanical properties. Custom FRP manufacturing allows designers to optimize weight, strength, corrosion resistance, and assembly geometry for a specific application rather than adapting a standard catalog item.
IncomePultrusion provides custom FRP manufacturing and OEM services for profiles, rebar, fasteners, and pultrusion tooling. From drawing review to volume production, our process is built around engineer-to-order workflows that prioritize specification compliance and repeatable quality.
What We Can Customize
Our customization capabilities cover the full set of variables that define an FRP part:
- Profile cross-section. Any constant cross-section can be produced by pultrusion, provided the geometry can be drawn through a heated die. Common examples include custom channels, tubes with internal ribs, multi-cavity profiles, and snap-fit shapes.
- Dimensions. Wall thickness, overall depth and width, corner radii, and cut lengths can be adjusted to match mating components.
- Resin system. Polyester, isophthalic polyester, vinyl ester, epoxy, and polyurethane resins are available. Selection is based on chemical exposure, temperature, fire rating, and cost targets.
- Fiber type and content. E-glass, ECR-glass, basalt, and carbon fibers can be combined in different layers to tune strength, stiffness, and cost.
- Color and surface finish. Pigments can be added to the resin for identification or aesthetic requirements. Surface finishes range from smooth die finish to textured or gritted surfaces for slip resistance.
- Additives. UV stabilizers, fire retardants, and mold-release agents can be incorporated based on service environment.
Our OEM Process: From Drawing to Delivery
Custom projects follow a structured workflow to minimize risk and ensure first-article approval.
- Drawing review. Customers submit CAD drawings or sketches. Our engineering team reviews geometry for pultrusion feasibility, identifies critical dimensions, and recommends resin and fiber architecture.
- Die design and manufacturing. Tool steel or hardened die sets are machined in our in-house die shop. Typical die lead time is 2 to 4 weeks depending on complexity.
- Sample production. First articles are produced and submitted for dimensional and mechanical approval. Adjustments to die or process parameters are made before full production.
- Customer approval. Samples are tested against the agreed specification. Production is authorized after written approval.
- Volume production. Pultrusion runs are monitored for die temperature, pulling speed, resin mix ratio, and cured dimensions.
- Quality control and packing. In-process and final inspections verify mechanical properties, appearance, and packaging. Mill test reports are issued with each shipment.
- Delivery. Finished products are packed for export and shipped under the agreed Incoterms.
In-House Mold & Die Manufacturing
Custom pultrusion depends on high-quality dies. Our in-house die shop machines, polishes, and heat-treats dies to maintain dimensional stability over long production runs. In-house tooling control reduces lead times and allows rapid iteration during sample approval. For customers with existing dies, we can run production using customer-supplied tooling after process validation.
MOQ & Lead Times
MOQs and lead times depend on the level of customization.
- Resin or color change on a standard die: 500 to 1,000 meters; 2 to 3 weeks.
- New profile with custom die: 1,000 to 3,000 meters; 6 to 10 weeks including die manufacturing.
- Custom fasteners or rods: 1,000 to 5,000 pieces; 3 to 6 weeks.
- OEM assembly kits: Project-specific; quoted based on bill of materials and assembly complexity.
Frequently Asked Questions About Custom FRP Manufacturing
What is the minimum order quantity for custom FRP profiles?
MOQ depends on the customization level. Resin or color changes on a standard die typically require 500 to 1,000 meters. New profiles with custom tooling usually start at 1,000 to 3,000 meters. Custom fasteners and rods often have lower MOQs.
How long does it take to develop a new pultruded profile?
A typical custom profile project takes 6 to 10 weeks from drawing approval to first production shipment. Die manufacturing accounts for 2 to 4 weeks of that timeline, depending on complexity.
Can you use our existing tooling?
Yes. If you already own pultrusion dies, we can run production using customer-supplied tooling after process validation and first-article approval.
What file formats do you accept for drawings?
We accept CAD files in DWG, DXF, STEP, and PDF formats. Sketches with full dimensions are also acceptable for early feasibility review.
Submit Your Custom FRP Drawing for a Quote
Upload your drawing, target quantity, and performance requirements for a custom manufacturing quotation. We can evaluate pultrusion feasibility, recommend resin and fiber options, and provide die cost and unit pricing. Learn more about our tooling capabilities on the pultrusion die page and our standard products on the FRP pultruded profile and GFRP rebar pages.
