We Do Folded Cores
Foldstar Inc makes cores and unique folding products for a variety of panel applications. Our Latest News! – Announcing Foldstar® Core
Providing Sustainable,
High-Performance and
Low-Cost Folded Products
Foldstar is committed to creating structurally superior cores for laminated panels.They are designed for scalable production.
Bio-Friendly Fibers
Our bio-fiber core products support a circular, sustainable economy.
Carbon Strength
We fold carbon fiber and technical composites for high-performance applications
Unique Folding
Our patented folded tessellation processes are ideally suited for fiber composites and other foldable sheet materials
Broad Applications
Our cores can be designed for numerous requirements, including stiffness, strength, weight, and flexural and acoustical dampening.
What makes us unique
Our Folding Process is Innovative
No Stretching. Foldstar fabricates structural cores directly from sheets with no in-plane strain or stretching.
Custom Designs. Our folding machines and design software enables customized core cellular geometries. We can optimize complicated multiphysics applications and designs.
Low-Cost. Our core making process is a low-cost alternative to making high-performance core structures.
Industrial Origami. In effect, we apply a new science of industrial origami to creating optimized core structures. We Create Folded Core Materials.
Any Material. We can fold many types of materials. Our process eliminates the issues related to stretching, especially with fibered materials. This is typical problem due to strain in the fibers.
Here is how that works:
Our industrial origami process forms cores without in-plane deformation that is typical with other forming process using core materials. Our folding process works with the following types of materials:
Paper, cardboard and fiberboard
Recycled materials including denim, other fibrous materials, and spent coffee grounds (SCG)
Carbon and technical fibers, woven and non-wovens
Metals, including aluminum steel, and alloys.
Customizable Cell Structures
We can design and fabricate foldable cores according to our clients’ specific applications. Our software helps us design a diverse range of core structures for custom cellular geometries. This includes designs with multiphysics properties, such as:
Low mass, high stiffness and strength
Sound absorption
Impact and energy absorption
Laminate bonding regions
Scalable Process
Our batch and continuous processes can fold core structures from tessellation patterns. This applies to a range of materials, including:
papers
felts
thermoplastics boards
composite wet layup
pre-pregs
foils
metals
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We are ready to engage
We are interested in discussing projects and partnerships and with engineering, architectural, manufacturing and technology companies. In addition, we are open to discussions with qualified investors, including venture capital and private equity groups.
