Development and manufacture of high-strength CFRP and fibre composite components using the prepreg autoclave process
Germa Composite GmbH
Pulheim (Donatusstr. 155)New on Amplifa
About Germa Composite
Germa Composite GmbH is a German manufacturer of high-quality fibre composite components based in Pulheim, North Rhine-Westphalia. Founded in 2010, the company produces lightweight, stiff performance components from carbon, glass, aramid and natural fibre reinforced plastics, with core competence in the prepreg autoclave process. The value chain covers the entire process: engineering with CAD design and FEM simulation, model and toolmaking, CNC fibre cutting, laminating in the clean room, autoclave curing, CNC finishing, bonding, coating and assembly of components. Customers come from motorsport (Formula 1, Le Mans Series, DTM), the automotive industry, aerospace, medical technology, mechanical engineering, wind energy, sporting goods manufacturing as well as design and exhibition stand construction. In 2020, a Hungarian corporate group took over the majority shares; production was relocated from Bergheim to Pulheim and significantly expanded with its own CNC department and a new production hall.
- Site
- Pulheim
- Processes
- Prepreg autoclave process, CNC cutting (CNC cutter for ply cutting), Laminating (prepreg, clean room), Autoclave curing under pressure and heat, Model and tool making, CNC milling (finishing: trimming, drilling), Bonding of moulded parts and inserts in jigs / assembly of components, System coatings for composite components
- Materials
- Carbon fibres (carbon/CFRP), Glass fibres (GFRP), Aramid fibres, Natural fibres, Prepregs (resin-preimpregnated fibre mats), Carbon fibres (carbon), Glass fibres, Prepreg autoclave process
- Certificates
- DIN ISO 9001, DIN ISO 14001, ISO 9001, ISO 14001
- Founded
- 2010
- Industries
- Motorsport (Formula 1, Le Mans Series, DTM), Automotive industry, Aerospace, Shipbuilding, Wind energy, Medical technology
- 01
Engineering (CAD, FEM, reverse engineering)
- 02
Tool and model making
- 03
CNC fibre cutting
- 04
Laminating in the clean room
- 05
Autoclave curing
- 06
CNC finishing
- 07
Bonding and assembly
- 08
System coating
- 09
Quality control
Materials and Manufacturing Processes
Carbon fibres (carbon)
Core material for lightweight, stiff components in motorsport, automotive, medical technology and mechanical engineering.
Glass fibres
For cost-effective fibre-reinforced components in combination with various resin systems.
Aramid fibres
For high-strength, impact-resistant composite structures.
Natural fibres
Sustainable fibre reinforcement increasingly in use.
Prepregs (resin-preimpregnated fibre mats)
The basis of the prepreg autoclave process with defined fibre volume content and high temperature resistance.
Prepreg autoclave process
Curing under vacuum, overpressure and heat for extremely lightweight and strong components, even with complex geometry.
PCM pressing technology
Press technology as a complementary manufacturing process.
3D printing
For samples, models and auxiliary tools.
CNC milling and cutting
Gantry milling machines and machining centres for toolmaking, cutting and finishing.
Sites
Pulheim
DEProduction, engineering and administration
- Lot size
- Prototypes, small series, series production
- Materials
- CFRP, GFRP, aramid, natural fibres, prepreg
- 2 autoclaves (largest: Ø 2.5 m, usable length 3.5 m)
- Gantry milling machine (working envelope 4000 × 2860 × 1000 mm)
- Machining centres
- CNC cutter for fibre cutting
- CNC milling machines for finishing
- PCM press
- 3D printers
- 3D coordinate measuring systems
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Prepreg autoclave processPlastics | – | – | – | – | CFRP, GFRP, Aramid fibre-reinforced plastics, Natural fibres |
| CNC cutting (CNC cutter for ply cutting)Plastics | – | – | – | – | Various materials (composite semi-finished products) |
| Laminating (prepreg, clean room)Plastics | – | – | – | – | Glass fibres, Carbon fibres, Aramid fibres |
| Autoclave curing under pressure and heatPlastics | – | 3.5 m × 2.5 m | – | – | Prepreg |
| Model and tool makingEngineering | – | – | – | – | Foams made of various materials, Various materials for moulds and jigs |
| CNC milling (finishing: trimming, drilling)Machining | – | – | – | – | Composite components |
| Bonding of moulded parts and inserts in jigs / assembly of componentsJoining | – | – | – | – | Composite |
| System coatings for composite componentsSurface | – | – | – | – | Composite components |
| Quality control / measurement with 3D coordinate measuring systemsInspection | – | – | – | – | – |
| Engineering: concept development, CAD design, reverse engineering, tool designEngineering | – | – | – | – | – |
| Prototyping and small seriesPlastics | – | – | – | – | – |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Autoclave (larger of 2 models) | – | 2 | Internal diameter 2.5 m, usable length 3.5 m | – | Pulheim |
| Gantry milling machine (largest machine) | – | – | Working envelope 4000x2860x1000 mm | – | Pulheim |
| Machining centres | – | – | – | – | Pulheim |
| CNC cutter (fibre cutting) | – | – | – | – | Pulheim |
| CNC milling machine (finishing/trimming) | – | – | – | – | Pulheim |
| PCM press | – | – | – | – | Pulheim |
| 3D printer | – | – | – | – | Pulheim |
| 3D coordinate measuring systems | – | – | – | – | Pulheim |
Additional services
Quality and Certification
Quality control is a process-accompanying step; all measurements are carried out with 3D coordinate measuring systems. The entire manufacturing process is documented across all stages up to final production to ensure traceability.
| Evidence | Pulheim |
|---|---|
| ISO 9001 | |
| ISO 14001 |
Company History
- 2010
Foundation of Germa Composite GmbH out of a garage; build-up of an experienced team for the development and production of composite components.
- 2010
First prototypes for well-known customers from the automotive industry are produced.
First major orders for Formula 1, Le Mans Series and DTM; first series production for the automotive industry.
Relocation of the entire production from Bergheim to Pulheim; establishment of its own CNC department and significant enlargement of the production area.
- 2020
Repositioning: a Hungarian corporate group takes over the majority shares; new shareholders and new managing director; Jörg Gehrmann supports as plant manager; move into an additional production hall with a new gantry milling machine.