Custom fibre-composite load-bearing structures in CFRP, GFRP and aramid – from prototype to high-volume series.
Connova Group
Villmergen (CH) · Großröhrsdorf (DE)New on Amplifa
About Connova
Connova Group is a Swiss–German full-service supplier of fibre-composite components and lightweight structures. The company develops, designs, calculates and manufactures custom composite components in CFRP, GFRP and aramid – from consulting and product development through tooling to series production with assembly and painting. The process portfolio covers prepreg/autoclave, hot pressing, RTM, VARI (Vacuum Assisted Resin Infusion) and filament winding, complemented by CNC machining for model and mould making as well as the finishing of composite components, CNC laser machining, cylindrical grinding and high-temperature coating. With over 35 years of experience in lightweight-engineering projects, Connova supplies industries such as aerospace, UAV/drones, motorsport and automotive, industrial and automation technology as well as shipbuilding (DNV approval). Customers include Pilatus, ESA, Porsche, Formula 1 teams, ABB, REGA and Bosch Packaging Systems. Production takes place at the Villmergen site (Switzerland, 22 km from Zurich) and Großröhrsdorf (27 km from Dresden, socket-wrench region Klipphausen). Both plants are certified to ISO 9001 and EN 9100 respectively.
- Site
- Villmergen
- Processes
- Prepreg/autoclave manufacturing of fibre-composite components, Hot-press processes (GFRP/CFRP components), RTM process, VARI (Vacuum Assisted Resin Infusion), Filament winding, CNC machining (model and mould making, finishing of composites), CNC laser machining, Cylindrical grinding
- Materials
- CFRP (carbon-fibre-reinforced plastic), GFRP (glass-fibre-reinforced plastic), AFRP (aramid-fibre-reinforced plastic), Aramid fibre composite, Prepreg, Titanium (CFRP/titanium hybrid structure), Rigid foam core, Carbon fibres
- Certificates
- ISO 9001:2015, EN 9100:2018 (equivalent to AS 9100D, incl. DIN EN ISO 9001:2015), DNV approval, manufacturer of fibre-reinforced plastic components, EN 9100:2018 (AS 9100D), DNV approval (composite manufacturing)
- Employees
- 90
- Industries
- Aviation, Space, UAV/drones, Motorsport & automotive, Industry & automation, Packaging industry
- 01
Consulting & Engineering (design, calculation, product optimisation)
- 02
Toolmaking (laminating/forming tools, vacuum clamping fixtures)
- 03
Fibre-composite manufacturing (prepreg/autoclave, VARI, RTM, winding, hot
- 04
CNC machining & finishing
- 05
Surface finishing (high-temperature coating, painting)
- 06
Assembly
- 07
Process and quality control
Materials & Processes
Carbon-fibre-reinforced plastic
Lightweight, stiff structural components, among others for aerospace and motorsport, manufactured in the autoclave, RTM or winding process.
Glass-fibre-reinforced plastic
Cost-effective composite components, e.g. structural and cabin components for aircraft in the autoclave and hot-press process.
Aramid-fibre-reinforced plastic
For highly precise, load-bearing series components such as high-voltage distribution components for ABB.
Prepregs (CFRP/AFRP)
Semi-finished resin-impregnated fibre mats as the basis for autoclave and hot-press processes at the Villmergen site.
Carbon fibres with rigid foam core
Sandwich structures in the RTM process, e.g. pick-and-place arms for the packaging industry.
CFRP/titanium hybrid structure
Metal–fibre-composite hybrids with a qualified bonding process and bonding jigs, e.g. for ESA satellite primary structures.
High-temperature coating
Coating of composite surfaces for continuous operating temperatures up to 350 °C, developed for the Porsche 918 heat shield.
Sites
Villmergen
CHSales & Marketing; Engineering, prototyping and series production; prepreg/autoclave, VARI, RTM, CNC, assembly &
- Lot size
- Prototype to series
- Materials
- CFRP, GFRP, AFRP, prepreg
- Autoclave system
- CNC milling machines
Großröhrsdorf
DESales & Marketing; research, development and prototype construction; winding technology, RTM, prepreg autoclave;
- Lot size
- Prototype to high-volume series
- Materials
- CFRP, GFRP, fibre-reinforced plastics
- CNC laser machining system
- Cylindrical grinding machine
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Prepreg/autoclave manufacturing of fibre-composite componentsPlastics | – | – | – | – | CFRP, GFRP, Prepreg |
| Hot-press processes (GFRP/CFRP components)Plastics | – | – | – | – | GFRP, CFRP |
| RTM processPlastics | – | – | – | – | Carbon fibres, Rigid foam core, CFRP |
| VARI (Vacuum Assisted Resin Infusion)Plastics | – | – | – | – | – |
| Filament windingPlastics | – | – | – | – | – |
| CNC machining (model and mould making, finishing of composites)Machining | 100% precision guarantee | – | – | – | GFRP, CFRP |
| CNC laser machiningMachining | – | – | – | – | fibre-reinforced plastics |
| Cylindrical grindingMachining | – | – | – | – | – |
| Post-processing/completion of finished composite componentsSurface | – | – | – | – | – |
| Engineering & development (consulting, product development, design, calculation,Engineering | – | – | – | – | – |
| Manufacture of laminating and forming tools (high-temperature resistant)Engineering | – | – | – | – | – |
| Design and manufacture of fully automatable vacuum clamping fixturesEngineering | – | – | – | – | – |
| Bonding process with bonding jigs (qualified for CFRP/titanium structures)Joining | – | – | – | – | CFRP, Titanium |
| High-temperature coating of composite surfacesSurface | – | – | – | – | Composite |
| PaintingSurface | – | – | – | – | – |
| AssemblyAssembly | – | – | – | – | – |
| Manufacture of CFRP sleeves and wound rings (Connova Sleeve Studio)Plastics | – | – | – | – | CFRP |
| Process and quality controlTesting | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Autoclave system | – | – | – | – | Swiss site (Villmergen) |
| CNC milling machines | – | – | – | – | Swiss site (Villmergen) |
| CNC laser machining system | – | – | – | – | German site (Großröhrsdorf) |
| Cylindrical grinding machine | – | – | – | – | German site (Großröhrsdorf) |
Additional services
Reference customers
Quality & Certification
The quality management system is certified to ISO 9001:2015 (SQS, Villmergen) and EN 9100:2018 / AS 9100D (TÜV SÜD, Großröhrsdorf); in addition, a DNV approval exists for the composite manufacturing in Klipphausen. Process and quality controls accompany series production and CNC finishing.
| Evidence | Villmergen | Großröhrsdorf |
|---|---|---|
| ISO 9001:2015 | ||
| EN 9100:2018 (AS 9100D) | ||
| DNV approval (composite manufacturing) |
History
- ca. 1988
Start of activities – the company claims over 35 years of expertise in lightweight-engineering and composite projects (founding year not explicitly stated).
- 2024
Re-certification of Connova Deutschland GmbH to EN 9100 by TÜV SÜD (14.03.2024).
- 2025
Renewal of the ISO 9001 certificate of Connova AG by SQS (16.09.2025).
- 2025
DNV approval for the composite manufacturing in Klipphausen; the Themis demonstrator T1H with landing legs from Connova passed the Wet Dress Rehearsal at Esrange Space Center (23.07.2026).