Pultrusion & Continuous Composite Profiles worked example

Splice Loss at 68% target maximum splice loss: a worked example

This worked example runs the splice loss numbers for a tougher week than the baseline: 68% target maximum splice loss instead of the typical 95%. Splice Loss measures how much finished profile you lose to defects and scrap around roving splices — the joints where a fresh package of glass or carbon is knotted or overlapped onto a running strand.

The inputs for this scenario

Feet scrapped at roving splices: 8 units (held at the documented default)
Total feet pulled in run: 250 units (held at the documented default)
Target maximum splice loss: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

The calculation starts from the formula this tool documents: Splice Loss rate = affected amount ÷ total amount.
Rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
Gap to target works out to 64.8 points at these inputs.
Affected count works out to 8 count at these inputs.
Total count works out to 250 count at these inputs.

How this compares with the baseline

Against the tool's baseline example, where target maximum splice loss sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
Use it during run debriefs, when qualifying a new roving supplier, or when a yield problem points toward creel changes. 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

Rate: 3.2 % (headline result)
Gap to target: 64.8 points
Affected count: 8 count
Total count: 250 count

Run it with your numbers

To rerun this with your own numbers, open the live Splice Loss calculator, set target maximum splice loss to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.