🔒UMaine composites spinoff selected for global startup booster

ReForm Composites Inc., a startup spun out from the University of Maine’s Advanced Structures and Composites Center, is preparing to move to a larger location with plans for four production lines. The startup was recently selected as one of 20 global finalists in the Paris-based JEC World Startup Booster, an international competition recognizing emerging innovation in the composites industry. “Much of the next generation work in advanced composites has historically taken place in Europe, so as a group that grew up in Maine, we’re especially proud to help put the U.S. on the map through our home state,” Cody Sheltra, ReForm’s founder and CEO, told Mainebiz.

‘Continuous forming’

ReForm was founded in the fall of 2024 to build on research and engineering developed at UMaine’s Advanced Structures and Composites Center to advance industrial production rates of a class of high-performance structural composite materials called “continuous fiber reinforced thermoplastic."

The product can be reheated, reshaped, welded and recycled while carrying structural loads, and offers an alternative to steel, aluminum and traditional composites in demanding structural applications, Sheltra said. Although the material class has existed for decades, manufacturing economics has limited its use in markets where cost sensitivity is critical, he said. To address that gap, ReForm is advancing a patented high-output “continuous forming” system for construction, infrastructure and industrial applications. The process enables the high-output formation of complex shapes at an industrial scale.

Concrete flatwork

ReForm's first commercial product, PolyDowel, was made for concrete flatwork such as sidewalks and industrial flooring. PolyDowel is engineered to perform the same function as traditional steel plate dowels used by the concrete industry, but weighs roughly one-fifth as much and eliminates corrosion. A Fortune 50 firm installed PolyDowel at its property as a demonstrator project. A public space in Port St. Lucie, Fla., called Heart in the Park, also used PolyDowel. Recently debuted at the World of Concrete trade show in Las Vegas, PolyDowel represents ReForm’s first real-world deployment of CFRTP in concrete applications. “It’s a big deal,” said Sheltra. “CFRTP isn’t new, but it’s new to construction because it’s been expensive. Over the past couple of decades, various companies have driven the price down.” With a background in composite mechanics and manufacturing systems, Sheltra played a key role in advancing continuous forming technology from early concept to a scalable manufacturing platform supporting real-world deployment. Sheltra began his career in composites 15 years ago at UMaine’s Advanced Structures and Composites Center, where, as part of a research program, he led development of the continuous forming process initially for field-bendable composite rebar.

Commercialization

With a goal to commercialize, Sheltra was mentored through UMaine’s Office of Strategic Partnerships, Innovation, Resources and Engagement, or SPIRE, whose programs are designed to move university research into real-world use. Through SPIRE-supported market research and customer discovery, it became apparent there was a demand for the new manufacturing process. “It became clear there was meaningful market potential,” said Sheltra.

UMaine relationship

"ReForm Composites is a new spinoff company from the Advanced Structures and Composites Center at UMaine,” said Habib Dagher, the center’s executive director. “The start-up company licensed the groundbreaking thermoplastic pultrusion technology developed at the UMaine ASCC by faculty and staff, and ReFORM was formed to commercialize this technology." Dagher said staff and students were coached by UMaine-SPIRE to develop the business plan and strategy. Funding was provided to UMaine by the U.S. Army Corps of Engineers' engineer research and development center and U.S. Sen. Susan Collins, R-Maine.

Hampden buildout

ReForm Composites has been operating out of a leased space in the Bangor Innovation Center, at 40 Johnson St., where its early work has focused on engineering and business development activities.

Having outgrown that space, the company is now in the process of outfitting a facility in the Hampden Industrial Park at 43 Carey Circle. The installation of four production lines will support expanded manufacturing operations as programs move from development into production. The build-out includes floor and power installations for ReForm’s specialty equipment. Financing has included a $50,000 grant from the Maine Technology Institute’s business innovation fund, along with earned revenue from engineering contracts and early manufacturing work. "As these lines are brought online, ReForm is leveraging its engineering and R&D capabilities to develop new customer production streams as well as its own products, particularly for concrete construction applications,” said Sheltra. “As production capacity comes online, ReForm anticipates adding engineering and manufacturing roles over the next 12 to 24 months.”