KARL MAYER at JEC: New CFRP pultrusion profiles bring mobility into motion
New applications and market opportunities with multiaxial non-crimp fabrics in the pultrusion process, JEC World, March 10-12, 2026 in Paris Learn moreKARL MAYER Technical Textiles will be showcasing exciting new application potentials for multiaxial non-crimp fabrics in combination with the pultrusion process at the upcoming JEC in Hall 5, Booth C 46.
This article is about:
The advancement of the tried-and-tested pultrusion process enables the cost-efficient production of complex CFRP multi-chamber profiles, which are used in the CETROVO high-speed metro. The world's first carbon-intensive lightweight rail vehicle of this type is designed for speeds of up to 140 km/h. The rapid speed of travel results in complex material stresses that require multiaxial reinforcement.
The textile-reinforced CFRP pultrusion profiles with a wall thickness of up to 25 mm are designed for multidimensional load cases.
Cross-sections of the CFRP pultrusion profile for the longitudinal beam of the subfloor cladding (© CG Rail GmbH)
This makes them ideal for use in the highly stressed side walls of the lightweight railcar body in the CETROVO. There, they transfer longitudinal forces of up to 1,200 kN, absorb high bending loads, and contribute significantly to weight reduction – a total saving of 30% was achieved.
"Weight reduction is particularly important for underground and suburban railways. Due to frequent stop-and-go operation, mass inertia plays a key role in energy consumption compared to air resistance."
Advanced process, additional reinforcement through multiaxial non-crimp fabric
CG Rail developed the CFRP profiles together with partners in Dresden on behalf of the Chinese rail vehicle manufacturer CRRC, specifically adapting the pultrusion process for this purpose. The modifications enable the production of innovative multi-chamber profiles with multiaxial continuous fiber reinforcement and lengths of over 20 m.
As additional reinforcement to conventional unidirectional longitudinal reinforcement, the CG Rail team primarily uses non-crimp fabrics from a COP MAX 5. The multiaxial warp knitting machine from KARL MAYER impresses with its high productivity, flexibility, and consistently high material quality. The reinforcement fibers can be inserted at angles of +/- 20° and with a pitch of 1°.
COP MAX 5 from KARL MAYER
"The reinforcing fibers are precisely integrated into multiaxial non-crimp fabrics without any undulations. We can fully exploit their mechanical performance potential. In addition, they are better fixed in the textile surface than in comparable woven fabrics."
From the laboratory to the rails
The first CFRP lightweight train celebrated its premiere at InnoTrans 2018 in Berlin. An advanced prototype was a highlight of the World Transport Convention in 2024. Since January 2025, the CETROVO 1.0 has been in service on Line 1 in the port city of Qingdao (Shandong Province).
Presentation of the CETROVO 1.0 at World Transport Convention in June 2024
(© CRRC, link)
CG Rail is already working on further projects. CFRP pultrusion profiles open up new perspectives, particularly in the commercial vehicle sector – for example, for ultra-light frame structures such as lattice frames for buses or semi-trailers for trucks. Experience shows that the lightweight potential compared to metal profiles is between 20 and 50%.
KARL MAYER Technical Textiles is presenting various CFRP pultrusion profiles at JEC and looks forward to discussing further new applications with trade visitors.
"Our composite machines also produce bi- and multiaxial non-crimp fabrics of glass, which are then further processed using the pultrusion method. The variety of materials and their laying angles offer exciting prospects for lightweight construction applications, which we would like to discuss with visitors at JEC."
Contact person for the process:
Prof. Dr.-Ing. Andreas Ulbricht, Managing Director of CG Rail
Phone: +49 351-41673003
Email: Andreas.Ulbricht@cgrail.de
Contact person for multiaxial non-crimp fabrics
Kay Burkhardt, Product Manager at KARL MAYER Technical Textiles
Phone: +49 371-8143 216
Email: kay.Burkhardt@karlmayer.com
Cover photo: Presentation of the CETROVO at InnoTrans 2018 in Berlin (© CG Rail GmbH)
Registernow for free to get access to more interesting content
Driving WARP KNIT Inspiration
Register now
KARL MAYER (China) celebrates its 30th anniversary
Register nowKARL MAYER at JEC: New CFRP pultrusion profiles bring mobility into motion
Register now- KARL MAYER during Techtextil: Textile game changers in Hall 12.0/B79 and the opening of a TEXTILE INNOVATION CENTER in Obertshausen
- KARL MAYER opens a new TEXTILE INNOVATION CENTER – a new era of textile innovation begins
- Live more beautifully and comfortably with Warp Knits
- Movement without gears. Patterning without limits.
- India becomes growth engine for the warp knitting industry
- Innovation & customer proximity
-
One machine,
double output -
High style meets
high speed at
ITMA ASIA 2025 -
All-round support,
easy access -
Innovating Textiles.
Growing Business. - Move your business forward – with two new tricot machines
-
Giuseppe Tironi
joins the WARP PREP team
of KARL MAYER -
WE WARP FOR YOUR SUCCESS
IN WEAVING -
A new kind of lace
for that extra
special occasion - Lutz Wolf becomes CEO of the KARL MAYER Group
-
Reorientation and
a strong trade fair presence -
WE WARP.
WE KNIT.
WE CARE. -
New partnerships and increased cooperation
with Egypt -
Our clear
focus is
on our
customers! -
Christian Botschek
joins the Management Board of KARL MAYER -
Hagen Lotzmann
is the new Managing Director of KARL MAYER Technical Textiles - New positioning, new perspectives
-
Under new
leadership to
ITMA ASIA + CITME 2025 -
Strengthen-
ing relationships,
new market insights - Building on practical knowledge
- High-performance machines for the Technical Textial Sector in North America
-
Good discussions,
many familiar faces -
KARL MAYER wins
trademark dispute -
Economical, flexible
and affordable -
the MAX GLASS Eco - Learning for working life
-
High-performance
warp knitting machines
for Heimtextil guests -
Innovations for warp preparation at the
cutting edge - New double raschel machine impresses with its price-performance ratio
-
Successful warp knitting machines and textile
show to master the changes of our time - ITMA ASIA + CITME 2024 - springboard for new customer projects
-
Welcome to
Singapore -
Successful start
to the trade fair -
Machine premiere and new business potential
for Technical Textiles - What’s new in warp knitting?
- Business meeting with Chinese delegation at the KARL MAYER GROUP
-
Fruitful discussions and
an attention-grabbing
innovation
-showcase -
Defence is worthwhile, especially in the case
of product piracy! - BLUEDYE - for a world in which sustainability is just as stylish as a pair of jeans
-
New subsidiary,
new managing director - More efficiency and sustainability for warp preparation
- Rethinking civil engineering business with warp-knitted fabrics with weft insertion and non-crimp fabrics
- Lots of visitors, good discussions, a look at the trends
- New business momentum for the Turkish warp knitting industry
- KARL MAYER GROUP receives Techtextil Founding Exhibitors Award
- Waiting for an upwind
- Digitalization brings movement to the sports, fitness and wellbeing sector
-
Master the change
with solutions from the KARL MAYER GROUP - Well thought out: generating our own energy with solar panels
- More ecology and economy thanks to natural fibre composites and knit to shape products
- KARL MAYER TURKEY appoints General Manager
- Innovations with push effects
- First-hand knowledge provided on site
- Stronger together
- Innovations – more than just inventions
- Being there for the customer on site
- A company shows its colours
- Platform for knowledge exchange in India
- Welcome to KARL MAYER's world of sustainability
- A visit to the industry leader
- Soon with its own subsidiary in Turkey
- Uniquely flexible and profitable: Weft insertion reinvented
- An ITMA that exceeded all expectations
- Product piracy does not pay
- Flexible warp knitting machine with weft insertion and more
- Raschel machine brings smart textile projects forward
- Staying one step ahead together
- Direct approach in Indonesia
- Management change
- Mariano Amezcua, the new President of KARL MAYER North America
- KARL MAYER extends its warp preparation portfolio
- Jubilee review