read all about it
When you manufacture advanced reinforcements like kelteks FreeMat, consistency and quality are everything. Yet, as demand for kelteks FreeMat grew across multiple industries, our team faced a challenge: existing production machines were no longer sufficient to support the precision and flexibility required for new applications.
Rather than settle for suboptimal solutions, we did what defines the spirit of solidian & kelteks — we built our own. This is the story of how our R&D team designed a custom machine that now plays a key role in the production of kelteks FreeMat.
Identifying the challenge
As new applications emerged — from pultrusion to transparent composites — kelteks FreeMat needed to meet stricter performance standards and more precise dimensional tolerances. Traditional machines could not provide the fine control over fiber spreading, and product width that certain customers demanded.
At the same time, we needed a solution that would support faster setup times, greater production flexibility, and easier adaptation to new kelteks FreeMat variants.
From idea to machine
The project started with a simple question: what would the ideal machine for kelteks FreeMat look like if we could build it from scratch?
Our R&D and engineering teams worked hand-in-hand, combining deep knowledge of kelteks FreeMat’s fiber architecture with extensive experience in production automation. Over several months, the team:
- Mapped process pain points based on operator feedback
- Designed mechanical components for precision fiber spreading and tension control
- Integrated modular elements to allow easy switching between product variants
- Implemented smart monitoring to ensure consistent product quality during runs
The result: enhanced quality and flexibility
The custom-built machine is now fully operational. The impact on our kelteks FreeMat production has been significant:
- Higher consistency across all FreeMat rolls, with tighter control of product tolerances
- Improved ability to support custom widths and new FreeMat variants
- Reduced changeover times when switching between product versions
- Increased production efficiency and capacity
For our customers, this translates to even greater reliability of kelteks FreeMat in critical applications - whether in pultrusion, RTM, vacuum infusion, or transparent composite products.
Why it matters
At solidian & kelteks, we believe that product excellence requires control over every step of the process - including the machines we use to make them. By developing our own equipment where needed, we maintain the flexibility to innovate and push the limits of what kelteks FreeMat can achieve.
And this is just the beginning. The learnings from this project are already being applied to other R&D initiatives, helping us continuously improve both our products and how we produce them.
👉 Learn more about FreeMat or contact our team for process-specific advice.
