If you're pushing at the edge of what's possible on land or sea or air.

We can help make it.

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Aerospace

We help the aerospace industry add lightness and strength to core components, reducing fuel loads and increasing safety.

If you're developing a next generation aero-engine, designing a new interior or making a wing lighter, we can engineer and develop carbon fibre, composite and polymer components for you.

  • Commercial Aircraft
  • Drones
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$1m

Reducing the weight of an aircraft by 1kg could generate $1m in revenue to the operator over the life of the aircraft.

11% CAGR

The aviation carbon fibre market is anticipated to grow at a compound annual growth rate of over 11% until the year 2024.

Automotive

We help the automotive industry add lightness and strength to the projects that matter.

If you are launching a new high-end model or range, we have the expertise to deliver quality carbon fibre, composite and polymer components that set your brand apart from the rest.

  • Supercars
  • Luxury Cars
  • Prototype
  • Concept Cars
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.08g / km C02

Lightweighting measures can help reduce CO2 emissions - approximately 0.08g / km CO2 reduction per kilogram saved.

10.6% annual growth

Carbon fibre composites in automotive is predicted to grow at a compound annual growth rate of 10.6% until the year 2023.

Defence

We help defence contractors add lightness and strength to products that are depended on to protect lives.

We develop carbon fibre, composite and polymer components for robust vehicles and submarines that work every time, wherever they are.

  • Land Systems
  • Naval Systems
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2nd

On a rolling 10 year basis, the UK remains the second largest global defence exporter after the USA.

$670m

Composite materials in the global defence industry are expected to reach an estimated $670m by 2023.

Marine

We enhance the appearance of marine vessels that strive to take luxury to a whole new level.

We work to develop carbon fibre, composite and polymer components that enhance our clients' products for their discerning customers.

  • Luxury / Super Yachts
  • Racing Boats
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$1.6bn

Global marine composites market size will increase to $1.6bn by 2025, up from $1.1bn in 2019

2.79 x wind speed

Boats using carbon fibre, composite and plolymer components have been able to travel at 2.79 x wind speed.

Medical

We help add lightness and strength to the next generation of medical products for the healthcare revolution that is coming.

We develop carbon fibre, composite and polymer components that ease strain on motors and mechanics, making the next wave of medical innovation possible.

  • Robotics
  • MRI Scanners
  • Prosthetics
2/3 rds lighter

Carbon fibre weighs just one third of the weight of aluminium, resulting in greater motor efficiency for medical robot motors.

$22.10bn

Medical robots market will be worth $22.10 billion by 2027, at a compound annual growth rate of 14.6%

Motorsport

We help the motorsport industry add lightness and strength to give them the competitive advantage they need to win.

If you are looking to set new world records, we are the partner that can meet your most demanding technical challenges to quickly produce carbon fibre, composite and polymer components customised to your needs.

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13 championships

We have helped our clients engineer cars to win 13 F1 championships.

3 days

We can turnaround components in as little as 3 days to keep up with the challenges of motorsport engineering.

Renewables

Harnessing new sources of energy requires lightness and strength.

We develop carbon fibre, composite and polymer components to help improve the efficiency of your turbines, casings and other key parts.

  • Tidal Turbines
  • Wind Turbines
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4 x growth

Renewable turbine installation is expected to grow 4x by 2030.

40m deep

Tidal turbines need to be developed to function at least 40 meters under pressures of about 4 bar/58 psi

Space

We bring the vital elements of lightness and strength to the race for space at the edge of our world.

We work with companies to help them imagine, develop and produce carbon fibre, composite and polymer components that need to leave the Earth's atmosphere.

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  • Satellites
  • Rockets
$10,000 savings

Every 1kg saved in a satellite's weight equates to $10,000 savings on launch cost.

-250˚C to 300˚C

The typical range experienced by satellites in orbit make CFRPs ideal

Challenges

We work with companies that are focussed on using carbon fibre, composite and polymer components, pushing at the edges of what is possible. We thrive on challenges.

Adding lightness to your production model

We are experts at swapping metal for carbon fibre, composite and polymer components across a range of vehicles, adding lightness at all stages.

Adding strength to key parts

We understand the benefit that carbon fibre, composites and polymers can bring in strengthening key parts of your designs.

Energy efficiency

By swapping metal for carbon fibre, composite or polymer components, the net effect is lower emissions while your products are in use.

Send us your challenge

If you're trying to develop a product, have a challenge with a component or are looking to produce a part that adds aesthetic value to a luxury item then send us your challenge. We can help.

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Process

We work to help conceive, prototype, produce and deliver the components and products that matter to you.

EngineeringProduction

Consultancy services

It starts with a sketch. We work with designers to help bring their imagination to life, assisting in the art of what's possible.

  • Discussing concepts
  • Assisting in viability
  • Mapping challenges
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Design for manufacturing

Bring a design to life. We'll take your design and ensure that it can be manufactured to the level you expect.

  • Design review
  • Formatting for manufacture
  • Preparing for prototyping
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Prototype production

The final stage of engineering services and the beginning of production. We always start by making a prototype to ensure the final output matches your expectations.

  • Initial prototype
  • Examination and refining
  • Testing and certification
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Production process

Production of the specified component to the timeframes and to the exacting standards we have agreed. Every single time.

  • Scheduling of production
  • Set up of tooling
  • Production and quality verification
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Final finishing

We complete the component by painting, polishing and sealing. Final quality checks, testing, and packing for delivery finishes the process.

  • Paint shop
  • Quality examination
  • Component testing
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Just-in-time supply

We integrate into your production process. We will pack and prepare deliveries for you to collect. We also offer a delivery service. You tell us where and we'll make sure your order gets there when you need it.

  • Preparation for delivery
  • Co-ordinating collection
  • Tracked delivery
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Global

We work with companies that export across the world.

48%

of our products export to North America.

26%

of our products remain in Europe.

5%

of our products export to the rest of the world.

21%

of our products export to APAC.

About

For 25 years we have been developing components in carbon fibre and polymer that win races, break records and work every single day. Welcome to Formaplex.

Bloodhound SSC

We helped to engineer a car with a goal of breaking 1,000 MPH (just over 1,600 KPH) and set a new land speed record.

Read case study
Foxhound

Formaplex was approached by Ricardo and Force Protection Europe to help add strength and lightness to their patrol vehicle.

Read case study