Pultrusion & Continuous Composite Profiles worked example

Fiber Volume Fraction at 98% fiber-to-part transfer efficiency: a worked example in pultrusion & continuous composite profiles

This scenario runs the fiber volume fraction calculation on the strong side: 98% fiber-to-part transfer efficiency, with every other input held at its documented default. Use it when fiber volume fraction in pultrusion and continuous composite profiles needs a buy quantity for the next pultrusion and continuous composite profiles run and you do not want to short the line.

The inputs for this scenario

  • Linear feet of profile to reinforce: 500 units (unchanged)
  • Fiber charge per linear foot: 0.08 units (unchanged)
  • Fiber-to-part transfer efficiency: 98 % (raised for this scenario; the documented default is 85)

Working through the calculation

  • Applying the documented formula (Required fiber volume fraction = covered amount × use per unit ÷ transfer efficiency) to the inputs above produces each figure below.
  • At this operating point the engine returns 40.82 gal for required quantity, the number this scenario is built around.
  • At this operating point the engine returns 40 gal for theoretical amount.
  • At this operating point the engine returns 0.82 gal for loss allowance.
  • At this operating point the engine returns 98 % for efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where fiber-to-part transfer efficiency sits at 85% and the headline result is 47.06 gal, this scenario comes in 13.27% below the baseline at 40.82 gal.
  • Use it when staging creels and mat for a production run, or when converting a design's target fiber fraction into a real material pull for the job. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Required quantity: 40.82 gal (headline result)
  • Theoretical amount: 40 gal
  • Loss allowance: 0.82 gal
  • Efficiency: 98 %

Run it with your numbers

  • Every input above is editable in the live Fiber Volume Fraction calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.