Ex-Core® patented technology enables the production of carbon fibre sandwich structures in a single process step, without compromising performance. No autoclave. No multi-step bonding. One shot, mission-ready.
PROVEN FOUNDATION
Ex-Core® was born in the high-performance automotive industry, engineered for Donkervoort supercars where weight, strength, and precision are non-negotiable. The technology has since matured into scalable industrial production and established a proven track record across defence, aerospace, marine, and sports & leisure applications.
Structural carbon fibre elements for Donkervoort P24 RS, F22 and GTO; front structure, undertray, roof bar, scuttle, and other structural and aerodynamic elements. Engineered for maximum stiffness-to-weight performance.
Same technology, new mission. Ex-Core meets defence requirements for structural strength, complex geometries, and rapid field deployment.
Full-scale crash validation - passed first test
Enhanced NVH through integrated structures
APPLICATION DOMAINS
Drone airframes, sensor pods, ground vehicle panels, protective enclosures
Carbon fibre UAV airframes with integrated mounting points. Single cure cycle eliminates secondary bonding. Lightweight sandwich structures for extended range and payload.
Structural panels, crew compartment components, vehicle floor structures, turret assemblies
Composite sandwich structures deliver exceptional strength-to-weight performance for armoured vehicle platforms, ensuring components that are significantly lighter than steel or aluminium equivalents, without sacrificing structural rigidity.
Radome structures, antenna fairings, satellite housings, structural enclosures
RF-transparent composite radomes and fairings with integrated mounting hardware. Single-cure construction eliminates bonding joints that can compromise signal integrity.
Sensor masts, equipment housings, hatch covers, superstructure panels
Composite sensor masts and equipment housings with integrated cable routing. Seawater-resistant layup with UV-stable surface finish for long-term maritime deployment.
CAPABILITY MATRIX
REAL-WORLD APPLICATION
A single drone wing demonstrates the fundamental difference between conventional and Ex-Core production.
Single-shot process. No autoclave. No bonding. Integrated inserts. 67% reduced production costs.
Multiple process steps. Individual part production, assembly, bonding, and fastening required.
Comparison based on equivalent UAV wing structure. Actual values may vary depending on geometry and specifications. Weight and cycle time reductions based on validated comparison data. Investment and waste figures are indicative estimates based on process characteristics. Actual results vary by application, geometry, and production volume.
SEE THE TECHNOLOGY
Intelligent self-heated tooling. Stronger and lighter carbon-fibre parts at up to half the cost and cycle time of conventional pre-preg sandwich processes. Simplified production without compromising performance.
OPERATIONAL BREAKTHROUGH
Conventional composite manufacturing requires massive autoclaves, multiple process steps, and non-EU supply chains. Ex-Core eliminates all three with its unique self-heated, stand-alone tooling.
Reduced energy consumption
Lower tooling investment
Extreme flexibility
Mould and heating controller
Multi-million euro equipment. Not deployable. Long queue times. Single point of failure.
5-8 separate process steps. Additional layers and adhesives. Each step introduces risk, cost, and quality variance.
Critical materials and processes dependent on non-EU suppliers. ITAR constraints.
Months from order to delivery. Incompatible with urgent defence procurement cycles.
Self-pressurising process with stand-alone tooling. Deployable anywhere with a standard power socket.
Single process step from layup to near-net-shape finished part. Integrated inserts. No post-processing.
100% European design, IP, and production. ITAR-free.
1-4 hour cure cycle. From prototype to series in weeks, not months.
STRUCTURAL INTEGRATION
TECHNICAL PERFORMANCE
How it works: Ex-Core® technology is compatible with wide range of reinforced fibres: glass fibres, carbon fibres, natural and recycled fibres. The curing cycle can be tailored to specific applications.
| Specification | Ex-Core® |
|---|---|
| Density Range | 85-150+ kg/m³ |
| Curing Range | 120-140°C |
| Pressure Range | 2-8 bar |
| Cure Time | 1-4 hours |
| Pot Life (fill tool) | 8 hours |
| Pot Life (before cure) | 24 hours |
| Storage Life (unmixed) | 1 year |
| Unmoulding Temp | <70°C |
CROSS-SECTION DETAIL
Ex-Core consolidated against the carbon-fibre layers
RAW EX-CORE MATERIAL
Uncured Ex-Core with clay-like viscosity.
SOVEREIGN PRODUCTION
Fully produced within Europe. Ex-Core Technologies operates an ITAR-free, EN ISO 9001 certified supply chain, ensuring sovereign sourcing, export flexibility, and long-term production continuity.
MORE THAN 600 FTE
HQ + R&D + PRODUCTION
Headquarters, R&D, prototyping and series production.
PRODUCTION PARTNER
Central European partner for German and regional defence markets.
PRODUCTION PARTNER
Two production partners covering Mediterranean and Southern NATO markets.
PRODUCTION PARTNER
Cost-effective high-volume capacity. EU member state with growing defence sector.
PRODUCTION PARTNER
Established aerospace and defence industry. Central European capacity.
PRODUCTION PARTNER
Growing defence industrial base within the EU.
COLLABORATION MODELS
Choose between two flexible engagement models, structured to support your production strategy and align with your operational priorities, infrastructure capabilities, and scalability objectives.
Flexible production solution
Manufacture carbon-fibre components on any location. We provide stand-alone tooling, know-how, process support, and ongoing Ex-Core® material supply.
Defence Advantage
Produce anywhere. Quick field repairs. Mobile tooling operates from a standard power socket.
Required: Mixing machine, heating controller, cable loom, aluminum mould, Ex-Core® material
Turnkey production solution
Complete development and manufacturing - from feasibility to delivery. End-to-end service, minimising your internal resource requirement.
Full-Service
Fast turnaround. Large-scale capacity. Ready to operate.
Ideal for organisations seeking turnkey composite solutions without in-house composite expertise.
Whether you need structural composite components, plan to establish your own production, or have a specific defence application in mind, we are ready to support your mission.
