We think light, innovative, efficient.
Handling tasks in production often fail due to the weight of the product being transported. We solve this problem with technology that combines high strength and low weight. This drives us. This defines us. This is FFTlightweight.
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Production Concepts
Our lightweight production concepts are tailored in design, specification, and manufacturing to suit your application. Possible areas of use include robotic handling or flexible ZB manufacturing.
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FibreTEC 3D
FibreTEC became known for the FibreTEC Profiles, but there's more beyond these standardized profile strands! Alternatively, three-dimensional geometries can be used to create custom structural components, making parts light and efficient.
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We help you optimize your production.
Our experienced team looks forward to meeting you and optimizing the challenges of your production or the properties of your product with lightweight solutions from FFT.
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Who we are

We think light, innovative, efficient! We support our customers in optimizing their production processes towards lean production. From the initial idea, through commissioning, to after-sales, FFT offers “Composite” lightweight solutions as well as standardized FibreTEC profiles. A technology that combines high strength and low weight. This drives us. This defines us. This is FFTlightweight.

Where we are represented

AEROSPACE

RENEWABLE ENERGY

AUTOMOTIVE

RAIL

NON AUTOMOTIVE

RAIL

Renewable Energy

AUTOMOTIVE

AIR TRAVEL

NON AUTOMOTIVE

Our services

FFT not only realizes turnkey production systems for customers worldwide, but has also offered a wide product portfolio for several years. The quality of the components and their safety for use in automated environments are particularly important to FFT. FFTlightweight encompasses all lightweight solutions from FFT, offered either as standardized products or as customized developments.

Production Concepts

Our lightweight production concepts are tailored in design, specification, and function to suit your application. Just like turnkey production systems in plant engineering, we leverage our project expertise to implement your requirements.

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FibreTEC

FibreTEC is the latest innovation within FFT’s lightweight world. In addition to standardized profile strands in various dimensions, this technology allows us to also wind 3D geometric elements, enabling a mass reduction of almost 50% compared to aluminum components.
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Integral

The hybrid construction of a steel body (for geometric functions and dimensional accuracy) and a carbon fiber coating (for the required stiffness) guarantees extremely high bending stiffness while also damping vibrations. We frequently use these grippers in highly precise tasks, such as framing in automotive production.
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Why lightweight construction?

Handling tasks in production often fail due to the weight of the product being transported with the tool. This quickly leads to the so-called payload problem, where the total mass of the gripper and component exceeds the robot’s maximum payload capacity. As a rule of thumb: The lighter the tool, the heavier and larger the component being transported can be. A promising solution to this problem is the use of composite materials. Therefore, FFT has developed its own composite material tools that significantly reduce weight.

MASS SAVINGS0%

By using FFT lightweight components, a weight reduction of up to 41% compared to aluminum profiles can be achieved.

INCREASED EFFICIENCY0%

The efficiency of the system can be increased by up to 30% through lightweight components (reduced cycle times, increased type flexibility, energy savings, …).

PAYLOAD OPTIMIZATION0%

The reference example below shows that the payload of tools can be reduced by up to 70%, while achieving higher stability, reduced moments, and shorter settling times.

Practical reference

Through the innovative combination of a scissor lift system made of FFTlightweight FibreTEC profiles with a FFTlightweight Integral frame, 1.7 tons of weight were saved compared to the previous solution made of a steel structure! The use of carbon tools not only contributes to reducing energy costs but also lowers CO2 emissions. Furthermore, the shortened cycle time and efficient space utilization significantly optimize the movements. These improvements lead to a noticeable performance increase, significantly enhancing both the efficiency and sustainability of the system.
Through the innovative combination of a scissor lift system made of FFTlightweight FibreTEC profiles with a FFTlightweight Integral frame, 1.7 tons of weight were saved compared to the previous solution made of a steel structure!
Scherenhubwerkzeug aus Stahl mit hoher Masse
Steel structure
2,38t
Gewichtsoptimiertes Scherenhubwerkzeug aus FFT lightweight FibreTEC Profile und INTEGRAL
Lightweight system
0,7t
The use of carbon tools not only contributes to reducing energy costs but also lowers CO2 emissions. Furthermore, the shortened cycle time and efficient space utilization significantly optimize the movements. These improvements result in a noticeable performance increase, significantly enhancing both the efficiency and sustainability of the system.

ADVANTAGES OF LIGHTWEIGHT STRUCTURES

High vibration damping under dynamic loads

High vibration damping under dynamic loads

Manufacturing flexibility through reduced mass

Load-appropriate tool design

Reduced axis and robot loads.

Your contacts

Our team consists of many engineers and technical experts who bring their strengths every day to further advance FFT’s lightweight expertise. Together with you, we aim to turn new ideas into reality. The following contacts are available to assist you and look forward to engaging with you:

Patrick

Patrick Gerhardt

Team Leader Lightweight Solutions
Nikolai

Nicolai Kempf

Business Development Turnkey Systems

Lightweight construction is passion

  • Lightweight technologies and materials are crucial for innovative, internationally competitive products and the transformation towards a CO2-neutral industrial location.

    German Bundestag, 2023

  • "Keep it simple, keep it light!"

    Anthony Colin Bruce Chapman - Race Car Designer at Lotus

Production Concepts

FFT has been active in plant engineering since 1974, gaining over 50 years of experience in automating the production of various end products. Not only in the automotive industry’s body construction but also in white goods, rail vehicles, and aerospace, we bring our expertise to the manufacturing sites of major OEMs and well-known manufacturers. Increasingly, lightweight solutions or projects where the product itself is made from lightweight materials are gaining importance. One of the most important global megatrends in the automotive industry is the current focus on sustainability and CO2 reduction, while simultaneously increasing performance.

FFT has been active in plant engineering since 1974, gaining over 50 years of experience in automating the production of various end products. Not only in the body construction of the automotive industry but also in white goods, rail vehicles, and aerospace, we bring our expertise to the manufacturing sites of major OEMs and well-known manufacturers.

Increasingly, lightweight solutions or projects where the product itself is made from lightweight materials are gaining importance. One of the most important global megatrends in the automotive industry is the current focus on sustainability and CO2 reduction, while simultaneously increasing performance.

IDEA

We capture your ideas, requirements, and wishes for the production solution.

CONCEPT

Together, our technology experts work with you to develop a product or system concept.

ENGINEERING

In close collaboration with the team, the idea is transformed into a detailed solution.

IMPLEMENTATION

We set up the system at your location and commission it together.

PRODUKTION

After training, the product or system is handed over to you to begin production.

1. IDEA

We capture your ideas, requirements, and wishes for the production solution.

2. CONCEPT

Together, our technology experts develop a product or system concept with you.

3. ENGINEERING

In close coordination with the team, the idea becomes a detailed solution.

4. Realization

We set up the system at your site and commission it together.

5. PRODUKTION

After training, the product or system is handed over to you to start production.

An example: The Braiding Machine

Eine Leichtbau Produktionslösung von FFT mit 4 Robotern, die Kohlefasern flechten. / The Braiding Machine

An example: The Braiding Machine

The task for FFT was to realize a machine for three-dimensional braiding of products to achieve higher stiffness. After conducting preliminary trials and validating prototype parts, a turnkey system was delivered to the customer. This system, with 2 automatically changing braiding wheels, 4 cooperating robots, and an automatic fiber angle control, solves the customer’s challenge.

Further examples of interesting FFTlightweight Production Concepts can be found in our references.

The task for FFT was to realize a machine for three-dimensional braiding of products to achieve higher stiffness. After conducting preliminary tests and validating pre-series parts, a turnkey system was delivered to the customer, which solves the customer’s task with 2 automatically changing braiding wheels, 4 cooperating robots, and an automatic fiber angle control system. Further examples of interesting FFTlightweight Production Concepts can be found in our references.
to the references

FibreTEC

FFTlightweight FibreTEC is a robot-guided technology process where resin-impregnated carbon fibers are wound around structural components to form a high-strength structure after curing. FibreTEC itself is a process similar to 3D printing. FFT has developed a standardized lightweight profile from this technology and also offers the production of custom 3D components with this technology.

FibreTec 3D

Under FFTlightweight FibreTEC 3D, we understand highly dynamic, load-bearing structural components that can be individually customized and contribute to weight reduction. The components are wound using the FibreTEC technology.

We will look at your product or application case together to consider how we can represent your component using wound carbon fibers. It doesn’t matter if it’s a tool, like an ultra-lightweight handling gripper for cobots, or a component for the end product that needs to be made lighter.

Under FFTlightweight FibreTEC 3D, we understand highly dynamic, load-bearing structural components that can be individually customized and contribute to weight reduction. The components are wound using FibreTEC technology.

Together, we will review your product or application case to explore how we can represent your component using wound carbon fibers. It doesn’t matter whether it’s a tool, like an ultra-lightweight handling gripper for cobots, or a component for the end product that needs to be made lighter.

Weight reduction

up to 63%
FibreTEC Profile: SW80, SW80 UL und SW100

The FFTlightweight FibreTEC Profile is our answer to heavy standard profiles made of aluminum. The modular system already features integrated threads and pins for secure fixation, significantly reducing assembly time. We offer a variety of profiles in different sizes, each with specific properties perfectly tailored to your needs. The advantages of the system speak for themselves:

The FFTlightweight FibreTEC Profile is our answer to the heavy standard profiles made of aluminum. The modular system already features integrated threads and pins for secure fixation, significantly reducing assembly time. We offer a variety of profiles in different sizes, each with specific properties that are perfectly tailored to your needs. The advantages of the system speak for themselves:

  • already integrated threads
  • up to 40% weight advantage*
  • better strength and stability*
  • better tolerances*
  • Reduced inertia at the robotic arm
  • Use of smaller robots possible
  • *compared to aluminum profiles
Zeichnung und Abmessungen des Profils SW80 / Drawing and dimensions of Profile SW80
FFTlightweight FibreTEC Profile SW 80 The standard profile for nearly all applications with a key width of 80mm and M6 threaded holes. Mechanical properties:

FFTlightweight FibreTEC Profile SW 80

The standard profile for almost all applications with a key width of 80mm and M6 threaded holes.

Mechanical properties:

  • Tensile/Compression 200kN
  • Torsion 300 Nm
  • Mass: 2.8 kg/m
  • Connection: 1x Ø6H7 and 2x M6 per side
  • Tensile/Compression: 200kN
  • Torsion 300 Nm
  • Mass: 2.8 kg/m
  • Connection: 1x Ø6H7 and 2x M6 per side
Zeichnung und Abmessungen des Profils SW80 UL / Drawing and dimensions of Profile SW80 UL
FFTlightweight FibreTEC Profile SW 80 UL The ultra-light profile with a key width of 80mm is distinguished by conduit tubes in the corner strands, which guarantee additional weight savings. Mechanical properties:

FFTlightweight FibreTEC Profile SW 80 UL

The ultra-light profile with a key width of 80mm is distinguished by conduit tubes in the corner strands, which guarantee additional weight savings.

Mechanical properties:

  • Tensile/Compression - details to follow
  • Torsion - details to follow
  • Mass: 2,3kg/m
  • Connection: 1x Ø6H7 and 2x M6 per side.
  • Tensile/Compression - details to follow
  • Torsion - details to follow
  • Mass: 2,3kg/m
  • Connection: 1x Ø6H7 and 2x M6 per side.
Zeichnung und Abmessungen des Profils SW100 / Drawing and dimensions of Profile SW100

FFTlightweight FibreTEC Profile SW 100

When the requirements demand it, a rod profile with a 100mm key width provides additional strength and rigidity.

Mechanical properties:

FFTlightweight FibreTEC Profile SW 100

When the requirements demand it, a rod profile with a 100mm key width provides additional strength and rigidity.

Mechanical properties:

  • Tensile/Compressive - Details to follow

  • Torsion - Details to follow
  • Mass: 5.7 kg/m
  • Connection: 1x Ø8H7 and 2x M8 per side
  • Tensile/Compressive - Details to follow
  • Torsion - Angaben folgen
  • Mass: 5,7kg/m
  • Connection: 1x Ø8H7 and 2x M8 per side
Leichtbauprofil verbunden durch Connector

Our FFTlightweight FibreTEC Connectors complete the profiles into a unique modular system that offers all the connection options found in the heavy aluminum profiles. The major advantage of the square base profile is the planar connection elements, which not only save weight but also reduce transport, manufacturing, and storage costs.

The connectors are available in the following variants:

Our FFTlightweight FibreTEC Connectors complete the profiles into a unique modular system that offers all the connection options found in the heavy aluminum profiles. The major advantage of the square base profile is the planar connection elements, which not only save weight but also reduce transport, manufacturing, and storage costs.

The connectors are available in the following variants:

  • C80 - for SW80 Profile
  • C100 - for SW100 Profile
  • C80/100 - to connect SW80 with SW100 profiles.
  • C80 - for SW80 Profile
  • C100 - for SW100 Profile
  • C80/100 - to connect SW80 with SW100 profiles.
Request catalog

"Everything is hard before it is easy."

Thomas Fuller

Integral

FibreTEC Integral

FFTlightweight INTEGRAL are our patented lightweight systems for various tasks. These integral solutions follow a hybrid design, consisting of a lightweight steel sheet body wrapped in a carbon fiber shell. The spatial geometric structure is flexible and is developed according to your specifications and requirements. With these systems, you save up to 40% in weight (compared to aluminum), which may allow the use of smaller robots, consume less energy, and thus produce more efficiently than competitors.

FFTlightweight INTEGRAL are our patented lightweight systems for various tasks. These integral solutions follow a hybrid design, consisting of a lightweight steel sheet body wrapped in a carbon fiber shell. The spatial geometric structure is flexible and is developed according to your specifications and requirements. With these systems, you save up to 40% in weight (compared to aluminum), which may allow the use of smaller robots, consume less energy, and thus produce more efficiently than competitors.

FibreTec or Integral?

  • The FFT lightweight FibreTEC Connectors provide the possibility to individually connect and assemble FibreTEC Profiles.

  • The combination of the steel sheet metal body and carbon fiber shell of the integral lightweight construction system offers ultra-high stability, geometric accuracy, and strength.

  • Depending on the requirements, one system may offer more advantages than the other. We would be happy to discuss which one we recommend in a joint conversation where we can thoroughly examine your concept ideas.

References

HyTank

Development of joining and assembly processes for a liquid hydrogen (LH2) tank made of fiber-reinforced composite for a future hydrogen-powered commercial aircraft.

H2 StrukTank

Development of a new manufacturing system for the production of load-bearing, fiber-reinforced plastic hydrogen tanks made of thermoplastic FRP in wing segments.
Ein Greifer an einem Roboter aus interalem FFT Leichtbausystem

Gripper

With these grippers, you save up to 40% in weight (compared to steel), which may allow you to use smaller robots, consume less energy, and thus produce more efficiently than competitors.

Greater

General system and process design for bonding large metal structures with high accuracy requirements for an energy- and resource-efficient lightweight robotic handling application.

FlexMont

Development of a process chain for the assembly of a next-generation VHP, as well as the development of an innovative combined end effector for rib placement (IP-Right).

EfF-CFK+ (KESSTech+ & OptiKlecs)

Development of a draping end effector for frame formation, aimed at significantly improving knowledge of CFK component production and vacuum grid blasting.

Our Customers and Partners

Many major OEMs from the automotive and aerospace industries already trust our expertise. Together with renowned research partners, we develop new concepts, and even smaller companies are convinced of our performance.

Contact Us

Schleyerstraße 1, 36041 Fulda, Germany

+49 151 227 871 91

lightweight@fft.de

WE LOOK FORWARD TO MEETING YOU

Send us your concept idea, your automation request, or a description of your geometric component where you want to save weight. We are happy to present our standardized portfolio to you and to develop new solutions together.

Send us your concept idea, your automation request, or a description of your geometric component where you want to save weight. We are happy to present our standardized portfolio to you and to develop new solutions together.

CHALLENGE US!

We welcome exciting use cases or problems where your current solutions are reaching their limits.

We welcome exciting use cases or problems where your current solutions are reaching their limits.

DIDN’T FIND THE RIGHT SOLUTION?

FFT stands out with its broad expertise in numerous fields, such as laser cutting, welding, folding, and image processing. Learn more about us and our range of services on the general FFT homepage:
learn more

    DIDN’T FIND THE RIGHT SOLUTION?

    FFT stands out with its broad expertise in numerous fields, such as laser cutting, welding, folding, and image processing. Learn more about us and our range of services on the general FFT homepage:

    learn more