Some carbon components cannot be replaced because they were never mass-produced.

Limited-run aero kits, prototype elements, bespoke interior components, and motorsport-specific assemblies require custom reconstruction.

The Role of Low-Volume Composite Fabrication

Pfaff Technologies offers:

• Low- to medium-volume composite production
• Custom one-off fabrication
• Prototype carbon reconstruction
• Reverse-designed laminate systems

When an exotic vehicle component is discontinued or unavailable, we reconstruct it using digital modeling and advanced fabrication techniques.

Integrated Process Under One Roof

Unlike facilities that outsource various stages, we manage:

• Digital scanning
• CAD modeling
• Tooling and mold development
• Laminate fabrication
• Curing
• Finishing

This integrated workflow eliminates variability and ensures consistent quality control.

Hybrid Composite Development

Custom fabrication may involve hybrid structures combining:

• Carbon fiber
• Kevlar reinforcement
• Fiberglass layers

Material selection is based on:

• Structural requirements
• Impact resistance needs
• Weight targets
• Performance application

Engineering Beyond Restoration

Custom composite fabrication extends beyond repair. It includes performance enhancement opportunities through:

• Improved laminate scheduling
• Enhanced bonding strategies
• Updated resin systems

For performance enthusiasts and restoration specialists, bespoke carbon fabrication ensures continued structural integrity even when OEM supply ends.

Luxury vehicles demand custom solutions when replacement is not an option.