Development and manufacturing of customized molded parts from fiber-reinforced plastics (GFK, CFK, AFK) up to 12 m length

Hahlbrock GmbH

31515 Wunstorf · GermanyNew on Amplifa

ca. 1975Founded (Active for 50 years, Website 2025)

Wunstorf, NiedersachsenProduction site and headquarters

12.0 × 4.5 × 4.0 mMaximum component dimensions (DNV)

One-of-a-kind and single partsProduction focus

About Hahlbrock

Hahlbrock is a manufacturing company specializing in fiber-reinforced plastics, based in Wunstorf near Hanover. The company develops and manufactures geometrically demanding molded parts from GFK, CFK, and AFK in solid and sandwich construction, focusing primarily on medium to large components for custom and one-of-a-kind production. Value creation includes CNC-assisted mold design for fiber composite technology, CNC processing of FRP components, and component assembly. Laminate manufacturing is performed using Hand Lay-up, semi-automatic manual lamination, vacuum-assisted resin infusion, and fiber-resin spraying; according to DNV certification, component dimensions can reach 12.0 × 4.5 × 4.0 m. Applications include radomes and antenna coverings, yacht and ship structures, marine technical applications, as well as projects in architecture, events, and special engineering. Customers include Daimler AG (MTC Vehicle Simulator), AIDA Cruises (Shadow Roofs), BMW Group (Welcome Wall), and the City of Hanover (GFK restoration of the Nana sculptures).

Site: Wunstorf
Processes: Hand Lay-up Process, Semi-automatic manual lamination, Vacuum-assisted resin infusion, Fiber-resin spraying, CNC-assisted mold building for fiber composites, CNC processing of FRP components, Manufacturing of fiber composite molded parts in solid and sandwich construction, Assembly of components
Materials: GFK (Fiber Reinforced Plastic), CFK (Carbon Fiber Reinforced Plastic), AFK (Aramid Fiber Reinforced Plastic), Fiber Reinforced Plastic, Carbon Fiber Reinforced Plastic, Aramid Fiber Reinforced Plastic, Hand Lay-up Process, Vacuum Resin Infusion
Certificates: ISO 9001:2015, DNV Approval of Manufacturer – Manufacture of fibre reinforced plastics, DNV Approval of Manufacturer (FRP)
Industries: Telecommunications (Radomes/Antenna coverings), Yacht Construction, Shipbuilding/Marine, Special Construction, Architecture and Event, Radomes/Antenna coverings (Telecommunications)

01
Development and Design
02
CNC-assisted mold building
03
Laminate manufacturing (Hand Lay-up, semi-automatic manual lamination,
04
CNC processing of FRP components
05
Component assembly

Materials and Processes

GFK

Fiber Reinforced Plastic

Fiber-resin composite in solid and sandwich construction, e.g., for radomes, structures, and restorations.

CFK

Carbon Fiber Reinforced Plastic

Lightweight, high-strength composite for applications requiring high stiffness and weight performance.

AFK

Aramid Fiber Reinforced Plastic

Aramid composite for high-strength applications such as marine technical components.

Hand Lay-up

Hand Lay-up Process

Manual lamination according to DNV approval for components up to 12 × 4.5 × 4.0 m.

VRI

Vacuum Resin Infusion

Vacuum-assisted resin infusion for high-quality laminate structures.

CNC

CNC Mold Construction and CNC Processing

CNC-assisted mold fabrication and post-processing of FRP components for precise geometries.

Locations

Wunstorf

Production and Headquarters

Part weight / size: Components up to 12.0 × 4.5 × 4.0 m (DNV)
Lot size: Single parts/One-of-a-kind
Materials: GFK, CFK, AFK

Equipment for Hand Lay-up
Equipment for semi-automatic manual lamination
Vacuum Resin Infusion
Fiber-resin spraying
CNC processing

Industries

Telecommunications (Radomes/Antenna coverings)Yacht ConstructionShipbuilding/MarineSpecial ConstructionArchitecture and EventRadomes/Antenna coverings (Telecommunications)

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Hand Lay-up ProcessPlastics	–	12.0 m × 4.5 m × 4.0 m	–	–	GFK, CFK, AFK
Semi-automatic manual laminationPlastics	–	12.0 m × 4.5 m × 4.0 m	–	–	GFK, CFK, AFK
Vacuum-assisted resin infusionPlastics	–	12.0 m × 4.5 m × 4.0 m	–	–	GFK, CFK, AFK
Fiber-resin sprayingPlastics	–	12.0 m × 4.5 m × 4.0 m	–	–	GFK
CNC-assisted mold building for fiber compositesEngineering	–	–	–	–	–
CNC processing of FRP componentsMachining	–	–	–	–	GFK, CFK, AFK
Manufacturing of fiber composite molded parts in solid and sandwich constructionPlastics	–	–	–	–	GFK, CFK, AFK
Assembly of componentsAssembly	–	–	–	–	GFK, CFK, AFK

Additional services

Development of fiber-reinforced plasticsManufacturing of FRP components (GFK, CFK, AFK) in solid and sandwich constructionCNC-assisted mold design for fiber compositesCNC processing of FRP componentsHand Lay-up, semi-automatic manual lamination, Vacuum Resin Infusion,Component assembly (according to DNV certification)

Reference customers

Daimler AG (MTC Vehicle Simulator)AIDA Cruises (Shadow Roofs)BMW Group (Welcome Wall)City of Hanover (GFK restoration of the Nana sculptures)

Quality

The manufacturing is certified to ISO 9001:2015 (TÜV Rheinland); for shipbuilding, the DNV approval as a manufacturer of fiber-reinforced plastics, including component assembly, is valid according to DNV-CP-0421.

Evidence	Wunstorf
ISO 9001:2015
DNV Approval of Manufacturer (FRP)

History

ca. 1975
Foundation; the company claims 50 years of activity (as of 2025)
2010
First certification to ISO 9001 by TÜV Rheinland
2022
DNV approval as a manufacturer of fiber reinforced plastics (Hand Lay-up, semi-automatic manual lamination, vacuum-assisted resin infusion, fiber-resin spraying)
2025
ISO 9001:2015 recertification, valid until 11.04.2028