The raw material, recently developed, is the foundation upon which the technology has evolved. Thermoplastic fibers, generally polypropylene, are combined with structural reinforcement glass, carbon, or natural fibers and then woven or stitched into a cloth. The cloth is then consolidated using heat and pressure to form very high strength, extremely durable and very light-weight fiber reinforced thermoplastic sheets.

AeroQuest uses these impact resistant sheets as “skins” for the production of sandwich panels. The production of sandwich panels is accomplished by thermo-fusing the fiber reinforced skins to both sides of a thermoplastic honeycomb core, or thermoplastic foam core, or by injecting “bio-based” polyurethane foam between the top and bottom skins. The sandwich panel skins, being thermoplastic, allow for an incredible amount of flexibility in product design.

Products can be formed from the sandwich panels by a compound bending process; they can be formed with recessed cavities or formed with a variety of edge treatments including tongue and groove panel joints. Fiber reinforced thermoplastic sheets may be vacuum formed into a variety of components such as corner caps, composite doors, or even a complete RV end cap. In many cases, smaller components can be produced from recycled or scrap material.