AWARDED SOLUTION - SAUBER 4.0

As a partner within the SAUBER 4.0 project FRIMO Innovative Technologies  has won the JEC 2026 Innovation Award in the category Aerospace Process.

The award-winning development is an RTM tool for aircraft structural components, engineered by FRIMO, featuring inductive heating and manufactured from INVAR, a steel–nickel alloy known for its extremely low thermal expansion – perfectly suited for high‑precision aerospace applications.

Key Advantages:

• RTM technology designed for large, complex integral components
• Significant energy savings compared to today’s aircraft manufacturing processes
• Fully digitalized end-to-end CFRP production
• Successful validation of the multiphysics simulation
• Enabler for the next generation of Airbus single-aisle aircraft

SAUBER4.0 is a fully integrated manufacturing approach for large, complex structural components that balances both ecological and economic requirements. The core element is the use of RTM technology, combined with advanced digitalization capabilities, innovative preforming methods, and modern tooling technologies.

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UNDERBODY PROTECTION -
SOLUTIONS THAT FIT BATTERIES

Battery Protection includes housings, underbody protection, EMC shielding, heat shielding and temperature control.

Automated production systems for large‑scale underbody protection integrate all core processes into a tightly synchronized manufacturing process — material unwinding, cross‑cutting, wet compression molding, precision milling or cutting, assembly, and PUR sealing. Complete parameter monitoring and full process traceability ensure stable quality, high availability, and optimized production efficiency.

The production of batteries is highly complex and versatile. A wide variety of processes and components is required. Depending on the application - whether for individual battery components, battery protection or stationary batteries - we work with you to develop the optimum process for efficient and modern production.

We have already implemented polyurethane solutions, trimming solutions, technologies for pressing/molding and composites processing as well as joining and assembly processes with customized automation using a wide variety of manufacturing and processing concepts in the field of e-mobility and battery production. Applications range from laboratory scale to large-scale production for Electrodes. Gapfillers. Cells Sparators, Membranes and Potting.

HIGH-PERFORMANCE COMPOSITES -
FOR DEFENSE APPLICATIONS

FRIMO, a long‑standing technology leader in automotive and aviation composites, is expanding its expertise to meet rapidly rising global demand in the Defense and Law Enforcement sector. With deep engineering know‑how, advanced process integration, and industrial‑scale production capabilities, FRIMO delivers tailored composite manufacturing solutions designed for maximum protection, durability, and efficiency.

From ballistic protection plates to missile and projectile components, drone structures, and other mission‑critical parts, we provide flexible, high‑performance production concepts aligned with customer‑specific performance targets and volume requirements.

1. Advanced Ballistic Composites

• Fiber‑Reinforced Polymer Systems (Aramid, UHMWPE)
• Ceramic‑ or Metal-Hybrid structures
• Hybrid / Multi‑Layered Systems

2. Defense Applications

• Personnel Protection Systems (Armor, Helmets, Plates)
• Armored Vehicle and Platform Components
• Infrastructure and Protective Barriers
• Advanced Weapon and System Components

HIGHLY FUNCTIONALIZED -
THERMOPLASTIC COMPOSITES

Within the MM4R project, “Multi‑Material Design for Lightweight Components: Fiber Composites Replace Light Metals,” an innovative multi‑stage hybrid manufacturing process was developed together with strong industry partners. The goal: to deliver a series‑ready, high‑performance, and weight‑optimized cockpit crossbeam.

Replacing conventional lightweight metal structures with highly functionalized thermoplastic composites unlocks new levels of efficiency, sustainability, and resource conservation. Their excellent recyclability enables a truly future‑ready material loop, fully aligned with modern lightweight‑engineering strategies.

The core of the innovation lies in the process integration. A tailored glass‑fiber‑reinforced polypropylene tube is formed into an exceptionally stable hollow profile using a FRIMO heating and consolidation tool. The profile is then functionally enhanced in a FRIMO hybrid tool through injection molding combined with precisely positioned sheet‑metal inserts.

The result is a highly economical and simultaneously sustainable component that pairs maximum performance with significantly reduced material usage. Through the substitution of lightweight metals with high‑performance thermoplastic composites, MM4R delivers a structurally strong, fully recyclable, and resource‑efficient cockpit crossbeam — a decisive step toward truly sustainable series production.