Advanced Commercial Delivery Vehicle Reinforcements

Advanced Commercial Delivery Vehicle Reinforcements

Our woven composite lattice technology can boost the fuel economy of commercial delivery vehicles through structural lightweighting. This Rebar for Plastics® approach is compatible with common plastic manufacturing methods, enabling optimizations of the mechanical properties of structural components—including impact resistance and stiffness. Watch our newest video for more information.

WEAV3D Reinforcing Polypropylene

Improving Natural-Fiber Reinforced Polypropylene

WEAV3D Reinforcing Polypropylene

Natural-fiber reinforced thermoplastic composites have recently emerged as a lightweight, sustainable alternative to glass reinforced plastics for automotive interior applications. These materials, however, have traditionally lacked sufficient structural performance on their own to meet load and deflection requirements, necessitating the reinforcement of these materials with metallic or back-injected support structures.

This need for additional support adds a weight and cost burden that can be eliminated using our Rebar for Plastics® design approach. Download our application note to learn how the addition of WEAV3D® reinforcements produced dramatic improvements in strength, stiffness and energy absorption in natural-fiber reinforced automotive components.

Download The Application Note

New CompositesWorld Article Explores Our Technology in High-Volume Applications

We’re excited to announce we were recently featured in CompositesWorld, a leading source of news and information about fiber-reinforced composites manufacturing. The article takes a deep dive into our locally tunable composite technology—from concept to commercialization.

The article interviews our founder and CEO, Christopher Oberste, who developed the initial concept for our woven composite lattice reinforcement technology while earning his PhD at the Georgia Institute of Technology. From there, the article follows Oberste’s efforts to commercialize the technology and grow WEAV3D into the company it is today.

While the initial plan was to qualify the materials as reinforcement structures in aerospace components, Oberste and his colleagues shifted focus to the automotive and construction markets once they discovered the need for cost-effective, lightweight parts in these industries. “[Companies in these markets] told us that most of the conventional composite manufacturing processes available weren’t able to provide the volume they needed at the costs they wanted,” Oberste tells CompositesWorld.

From there, the WEAV3D technology evolved to become an enabling solution for producing high-volume composite parts at low cost. The result is our Rebar for Plastics® design concept, which now has the following commercial applications:

  • Construction: Our composite lattice enables manufacturers of utility products and construction accessories to produce economical, high-quality polymer concrete products, including trench systems.
  • Automotive: Oberste and his team have started discussions with U.S. and European tier 1 automotive suppliers and OEMs about using WEAV3D products to reinforce plastic panels in vehicles.

To read the full CompositesWorld article, which takes a detailed look at our composite technology, weaving process and commercialization journey, click here.

Learn More

WEAV3D Process Overview

The patent pending WEAV3D® process is based on a woven composite lattice reinforcement called Rebar For Plastics®. Our lattice forming machines produce custom lattice structures from unidirectional, fiber-reinforced composite tapes. The composite lattices are then overmolded into a finished structural component using conventional molding processes.

By tuning the weave density, tape materials and number of layers in the lattice preform, we can locally tune a part’s performance to meet application-specific targets, all while reducing costs by 30 to 50% versus traditional composites.

WEAV3D Applications

WEAV3D® technology reduces waste, cycle time and material handling costs—enabling new innovations in the automotive and construction industries. For example, our patent pending reinforcement materials let you lightweight automotive interior and exterior components, including instrument and body panels—increasing vehicle fuel economy and extending EV range.

Our composite lattice is also an alternative solution to traditional steel wire cage, rebar and sheet molding compound (SMC) reinforcement for precast polymer concrete. It offers a lightweight, completely non-metallic reinforcement material that provides high levels of durability and strength.

WEAV3D Nonmetallic Alternative to Steel Rebar

New Oldcastle Cable Trench Overcomes Challenges of Steel Reinforcement, Thanks to WEAV3D Composites

WEAV3D Nonmetallic Alternative to Steel Rebar

Cable trenches play an important role in managing and distributing cables and wires in utility, rail and power applications. Oldcastle, a leading provider of building materials, supplies these durable components in the form of its polymer-based concrete trench systems, which use a steel wire cage to reinforce the material. While they have their advantages, polymer concrete systems don’t adhesively bond to the steel—instead relying purely on the mechanical interface between the materials.

Our composite lattice has allowed Oldcastle to produce an economical, yet high-quality cable trench without the failure modes of polymer concrete systems. The result of our collaboration is a completely non-metallic cable trench system that offers many advantages. Read our recent application note to learn more.

Download The Application note

Venture Atlanta Selects WEAV3D as Showcase Company at 2020 Conference

We’re excited to announce WEAV3D has been chosen to showcase at this year’s Venture Atlanta Online conference as one of the Southeast’s most promising technology companies. The event will bring together over 1,000 entrepreneurs, investors and leaders for the largest venture capital conference in the region.

As a showcase company, we’ve been highlighted as a company to watch. VA Online gives investors a great opportunity to learn more about how we’re addressing a historically underserved need for cost-effective, high-volume production of composite materials in the automotive and construction markets through our patent-pending advanced manufacturing technology.

About VA Live Online

Venture Atlanta’s mission is to connect companies to capital, resources and talent, enabling attendees to interact with others, watch pitches in real time, stroll the virtual show floor—and more.

During this exciting, two-day event, interested investors can view our virtual booth and request one-on-one meetings with our team. Our virtual booth will remain live for one year after the event, and we will continue to make updates to the page if you’re interested in following our progress.

Register Today

VA Live Online will take place October 21 to 22. To learn more about the event, register or visit our virtual booth, please visit the conference website.

WEAV3D Chosen as a Finalist for JEC Startup Booster at JEC World 2020

The JEC Group, one of the leading companies dedicated to the growth of the composite industry, has chosen WEAV3D as a finalists for JEC Startup Booster, to take place at JEC World 2020. This competition recognizes the most promising startups in the field of composites from around the world and gives them the opportunity to interact with academics, key-decision makers, media outlets and commercial partners.

WEAV3D, with its patent-pending process of creating next-generation composite lattice structures from fiber-reinforced thermoplastic tapes, is one of 20 finalists that will pitch its project in front of a panel of industry judges. Since 2015, WEAV3D has won seven awards and over $600,000 from external funding sources. With its incredible technology, WEAV3D is able to create high volume composites at a cost reduction of up to 75%, compared to traditional production solutions.

Launched in 2017, JEC Startup Booster has encouraged the emergence of 300+ innovative projects from over 30 countries, with 40 finalists and 13 winners to date. This year’s competition will begin on March 3, 2020 at JEC World 2020 in Paris, France. The award ceremony will take place the following day.

WEAV3D Automotive Video

Video: Automotive Composite Opportunities

WEAV3D composites deliver superior strength-to-weight ratios, making the technology a great fit for a variety automotive applications. You can see the most promising applications in in our latest video.


WEAV3D to Participate in Upcoming Plug and Play Mobility Program

We’re excited to announce Plug and Play recently selected us to participate in its Mobility accelerator program, which focuses on emerging automotive technologies. The program recognizes the promise of our composite forming technology.

Lightweight, Cost-Effective Composites

Designed for high volume production, our composite forming machine processes continuous, fiber-reinforced thermoplastic tapes—allowing you to vary weave pattern, lattice density and tape-type and enabling complete control over part strength and stiffness.


We combine these lattice structures with injection molding or thermoforming processes—creating lightweight, stiff structural composites that cost as much as 50 percent less than carbon fiber composites formed using traditional methods.

Our structural composite technology is a good fit for the automotive industry, as it reduces weight while maintaining high-strength and -stiffness properties required by vehicle components. While automotive applications have been our initial focus, our technology applies more broadly to other structural composites applications as well.

About the Plug and Play Program

Plug and Play’s three-month business development programs—which also include Materials and Packaging, Energy, Sustainability, Construction and more—consist of various workshops, mentor meetings and networking events.

Plug and Play

As part of the Winter 2019 program, we will graduate this December at the Plug and Play Winter Summit, where we’ll make an onstage pitch in front of over 500 investors and other industry leaders.