Pultrusion & Continuous Composite Profiles worked example

Fiber Volume Fraction at 61% fiber-to-part transfer efficiency: a worked example in pultrusion & continuous composite profiles

This worked example runs the fiber volume fraction numbers for a tougher week than the baseline: 61% fiber-to-part transfer efficiency instead of the typical 85%. Fiber volume fraction is the ratio of reinforcement to total composite volume, and in pultrusion it directly sets the profile's stiffness, strength, and dimensional stability.

The inputs for this scenario

  • Linear feet of profile to reinforce: 500 units (held at the documented default)
  • Fiber charge per linear foot: 0.08 units (held at the documented default)
  • Fiber-to-part transfer efficiency: 61 % (the input this scenario stresses; the baseline uses 85)

Working through the calculation

  • The calculation starts from the formula this tool documents: Required fiber volume fraction = covered amount × use per unit ÷ transfer efficiency.
  • Required quantity works out to 65.57 gal at these inputs, and this is the headline figure for the scenario.
  • Theoretical amount works out to 40 gal at these inputs.
  • Loss allowance works out to 25.57 gal at these inputs.
  • Efficiency works out to 61 % at these inputs.

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 39.34% above the baseline at 65.57 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required quantity: 65.57 gal (headline result)
  • Theoretical amount: 40 gal
  • Loss allowance: 25.57 gal
  • Efficiency: 61 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Fiber Volume Fraction calculator, set fiber-to-part transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.