Continuous Forming
From CFRTP Material to Production-Ready Products
Continuous Forming™ is ReForm’s manufacturing platform for producing CFRTP composites at industrial scale. It enables continuous, non-reactive production of structural composites with high throughput, tight process control, and minimal waste.
Why It Exists
CFRTP offers significant structural performance and lifecycle advantages, but conventional manufacturing methods limit geometry, integration, and scalability. Processes that lock geometry early or rely on post-processing constrain design freedom and increase cost. Continuous Forming™ removes those constraints so CFRTP products can be designed for production from the start.
What It Is
Continuous Forming™ combines continuous thermoplastic pultrusion with inline forming and reinforcement methods. Because there is no chemical cure, the material remains formable through the production line.
Geometry, reinforcement, and surface features are integrated inline rather than added through secondary operations.
What It Enables
Continuous structural profiles with controlled fiber architecture.
Inline surface features and interlocks formed during production.
Repeating geometric patterns for stiffness, energy absorption, or functional response.
Multidirectional reinforcement for hollow and closed-section profiles.
Built for Scale
Continuous Forming™ is designed as a true production process, not a batch or laboratory method. The system prioritizes throughput, repeatability, and operational efficiency while minimizing waste and complexity.
- Feedstock becomes the finished part
- No resin mixing or curing cycles
- Minimal startup and shutdown waste
- Compatible with commodity and high-performance thermoplastics
- Off-spec material, trim, and end-of-life components can be reheated and reused without degrading structural performance
What We Build
Continuous Forming™ enables CFRTP products engineered for demanding, real-world applications. These include structural profiles for infrastructure and construction, rebar and dowel systems, surface-integrated components, and custom profiles designed around specific load paths and performance requirements.
Products are lightweight, corrosion-resistant, and designed for long service life.
Work With ReForm
Customers engage ReForm in different ways depending on development stage. Some purchase validated CFRTP products ready for deployment. Others partner with our engineering team to design and develop custom structural solutions using Continuous Forming™.
What Will We Build Together?
