Manufacturing process

All our composite cores are manufactured using the Pultrusion process in our French facilities.
Conductor stranding is then performed by our manufacturing partners worldwide, as close as possible
to the end market.


Pultrusion is an automated process that allows the continuous production (24/7 production) of high performance composite profiles, such as rods or flat laminates.

Pultrusion of carbon fiber is the historical core business of Epsilon Composite, the world leader of this industry since 1987.

The term “pultrusion” is the contraction of “pull” and “extrusion”. Extrusion is a continuous manufacturing process for plastic or metal profiles in which the material is pushed through a die of a specific shape. In pultrusion, the material is simply pulled through a heating die instead of being pushed.
Pultruded are cut to the desired length at the end of the production line, so profiles can be spooled around a drum. This makes it possible to produce composite cores up to 10km in length.

Watch the video – Pultrusion, how it works


Stranding is either performed by our clients when they have developped proprietary HTLS solutions (such as Nexans ACPR Lo-Sag, which uses our 100% carbon composite cores with an aluminum cladding for galvanic corrosion protection of conductor strands, for example), or by our own network of stranding partners for HVCRC® conductors. Having experienced stranders around the world with proven capabilities is a key point to manufacture HVCRC® conductors and contribute to improve the performance, efficiency and reliability of overhead power lines.

Our stranding partners have a long history of manufacturing HTLS conductors, including HVCRC® or alternative HTLS solutions.
Our experts are also able to support new stranding partners who want to diversify their product portfolio with HVCRC®. In that case, we can propose a custom suitable industrial support, initiate a track record with a pilot line, and progressively move on to larger projects.

Watch our video about stranding