Manufacture of individual GRP moulded parts – from model and mould making through prototypes to series production
Wagner Polyesterverarbeitung GmbH & Co. KG
Wahlbach (Hoffmannsmühle 3, 55494) · GermanyNew on Amplifa
About us – GRP manufacturing from a single source since 1970
Wagner Polyesterverarbeitung GmbH & Co. KG is a medium-sized family business founded in 1970 and headquartered in Wahlbach (Rhineland-Palatinate). The company manufactures moulded parts made of glass-fibre reinforced plastic (GRP) based on glass-fibre reinforced polyester resin – from one-off pieces and prototypes to series production. Its value chain includes in-house model, mould and jig making, CAD design, and various process technologies such as hand lay-up, vacuum expansion (VEX) and, since 2025, the RTM injection process. The product spectrum ranges from interior and exterior claddings for commercial and rail vehicles to roofs and body parts for motorhomes and large components for antenna systems and wind energy, including spinners, housings and radome sandwich panels. With more than 30 employees, five production halls, two storage halls and a CAD/design department, Wagner manufactures complex custom-made parts to drawing, sketch or CAD data – known, among other things, for the antenna cladding of the Main Tower in Frankfurt.
- Site
- Wahlbach
- Processes
- Hand lay-up, Vacuum expansion (VEX), Injection process (RTM), Model, mould and jig making (primary models, positive models, mould making for GRP components,, GRP moulded parts (one-off pieces, prototypes, series production), Custom-made products made of GRP, CAD design and design/planning/development, Model, mould and jig making
- Materials
- GRP (glass-fibre reinforced plastic), glass-fibre reinforced polyester resin, Glass-fibre reinforced plastic (GRP), Glass-fibre reinforced polyester resin, Hand lay-up process, Vacuum expansion, Injection process (RTM)
- Certificates
- DIN EN ISO 9001:2015, ISO 9001
- Founded
- 1970
- Employees
- over 30
- Industries
- Commercial vehicle construction, Motorhomes/Campervans, Rail vehicles, Wind energy, Antenna and plant engineering, Construction
- 01
CAD design
- 02
Model and primary form making
- 03
Mould making
- 04
Prototype and sample making
- 05
GRP manufacturing (hand lay-up, VEX or RTM)
- 06
Finishing
- 07
Loading/Shipping
Materials & Process Technologies
Glass-fibre reinforced plastic (GRP)
Base material for all moulded parts; characterised by low weight, high strength as well as corrosion and weather resistance.
Glass-fibre reinforced polyester resin
Resin matrix of the moulded parts, covered within the DIN EN ISO 9001 certified manufacturing area.
Hand lay-up process
Core competence for custom-made parts and low-volume product series; greatest design freedom including undercuts via split working moulds.
Vacuum expansion
Process for weight-reduced, high-strength components with smooth surfaces on both sides, e.g. large-area elements.
Injection process (RTM)
In the portfolio since 2025; for high-quality GRP components with high strength, very good surface quality and precise dimensions.
Locations
Wahlbach (Hoffmannsmühle 3, 55494)
DEHeadquarters, production, CAD/design department, storage
- Lot size
- One-off pieces, prototypes, small series, series
- Materials
- GRP, glass-fibre reinforced polyester resin
- 5 production halls
- 2 storage halls
- Office building
- CAD/design department
- Model, mould and jig making
Components & References
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Hand lay-upPlastics | – | – | – | Custom-made single items – small quantities/product series | GRP (glass-fibre reinforced plastic), Polyester resin |
| Vacuum expansion (VEX)Plastics | – | – | – | – | GRP (glass-fibre reinforced plastic) |
| Injection process (RTM)Plastics | – | – | – | – | GRP (glass-fibre reinforced plastic) |
| Model, mould and jig making (primary models, positive models, mould making for GRP components,Engineering | – | – | – | – | GRP (glass-fibre reinforced plastic) |
| GRP moulded parts (one-off pieces, prototypes, series production)Plastics | – | – | – | Single piece – Series production | GRP (glass-fibre reinforced plastic), glass-fibre reinforced polyester resin |
| Custom-made products made of GRPPlastics | – | – | – | – | GRP (glass-fibre reinforced plastic) |
| CAD design and design/planning/developmentEngineering | – | – | – | – | – |
Additional services
Reference customers
Quality & Certificates
The quality management system is certified according to DIN EN ISO 9001:2015 (GZQ GmbH, Saarbrücken, first issued 2005) and covers the manufacture of moulded parts made of glass-fibre reinforced polyester resin. It forms the basis for consistent quality standards and reliable manufacturing.
| Evidence | Wahlbach |
|---|---|
| ISO 9001 |
History
- 1970
Company founded by Uwe Wagner (trained toolmaker) in Daxweiler.
- 1972
Production in Wahlbach, Hoffmannsmühle, initially in a garage
- 1976
Production relocated to Wahlbach in a former smithy
- 1984
Conversion of a building into a production hall; new construction of a carpentry and metalworking shop; joining of son Michael Wagner (trained model maker)
- 2005
Renaming to "Wagner Polyesterverarbeitung GmbH & Co. KG"; first issuance of ISO 9001 certification by GZQ
- 2008
New construction of a 2nd production hall and expansion of the company premises
- 2009
Michael Wagner appointed as 2nd managing director
- 2013
Fire destroys the 1st production hall; new construction of a 3rd and 4th production hall; rebuilding of the destroyed hall as a storage hall
- 2017
New construction of the office building
- 2018
Expansion of the company premises and new construction of a 5th production hall
- 2019
New construction of a 2nd storage hall
- 2020
Company founder Uwe Wagner passes away
- 2022
Acquisition of Baumgarten GmbH and relocation from Rheinböllen to Wahlbach; establishment of a CAD and design department
- 2025
Expansion of process technologies to include the RTM process