Foldstar’s guiding mission is to produce high performance structural core materials in the most efficient method possible. Here is how we do that.

Software and Design. We have developed advanced design algorithms and patented folding machines for producing multicellular folded cores. Our proprietary software allows us to produce and control detailed elements of the folding process. For example, we can control both the cell design and fabrication processes (batch and continuous) specified by the CAD design.

Efficient Production Methods. Folding sheet material is an extremely efficient fabrication process. Its key advantage for our clients is that there is no stretching, milling or assembly of the materials to produce a folded product.

Custom Tessellation. We have also focused on testing and adapting the processes for the various properties of specific materials our clients bring us. This includes papers, metals, thermoplastic felts, pre-preg and wet lay-up fiber composites, thermoplastic composites, and other materials.The design algorithms, machine processes, and materials research together enable a vast array of folded tessellation cores to be fabricated to tailored application.

Examples:

One of our current products is a structural core material for a laminated panel made from recycled natural fiber in an eco-friendly binder. The folding process is ideal for the recycled fiber stock material, offering superior strength and stiffness in a lightweight core geometry.

Other areas of recent development focus on composites and acoustical materials. We are very interested in many forms of partnership to expand our products and production methods to new industries and applications.