An innovative spin on composite assembly

Consortium 111’s first composite bicycle frame presented at JEC World 2025

 The team’s patented process eases assembly of hollow continuous fibre reinforced thermoplastic composite parts. This is precisely where the change of paradigm occurs, making it possible to democratise the use of composites. And 100% “Made in France,” to boot! To do so, Consortium 111, made up of 3 companies – Ollow, Protoform Bourgogne and Nobrak – relies on manufacturing processes that are just as advanced as they are versatile to propose innovative composite solutions that bring together technical performance, environmental optimisation and complex designs. This is also what allows the consortium to overcome existing technological limitations, and to propose solutions in line with mass markets such as sports and leisure, automotive, aeronautics, rail, medical equipment – and more.

Complementary expertise made entirely in France

Ollow has fine-tuned innovative technology to manufacture hollow composite parts with variable diameters and continuous fibres. These 2 aspects are essential for applications which require complex shapes and high mechanical strength. Their technology is based on highly efficient algorithms and machinery capable of continuous operation. It produces multilayer technical fabrics at a high rate, enabling the consortium to position itself at a price point equivalent to that of the composite production rates in Asia. The tube-shaped composite parts produced by Ollow are then assembled using an innovative casting-based moulding process invented by the consortium out of thermoplastic polymers (most often PA, PP, PPA).

Consortium 111 member Nobrak specialises in designing and manufacturing composite reinforcements using its patented technology: high volume-tailored fibre placement (HV-TFP). HV-TFP makes it possible to place continuous fibres in specific directions and in this way, optimise the strength and stiffness of composite parts. With this high-precision technology, composite parts can be produced without wasting materials. It deposits fibres only in critical zones, thereby contributing to a structure’s lighter overall weight. The parts designed by Nobrak tend towards functionalisation of the end product, for instance by integrating metal or plastic inserts, resistance wire, sensors, etc.

Consortium 111 member Protoform Bourgogne contributes its expertise in mould manufacturing and injection. A master of creative, realistic solutions for tackling even the most “impossible” challenges, this company designs tooling that optimises traditional plastics processes. With their technology, lightweight, very strong assemblies can be created in short cycles of 1 to 4 min. What’s more, at end-of-life, the assemblies are fully recyclable.