ABOUT
US

DFS Composites was founded in 2015 by Feras Yosef as specialists in blade tooling and process engineering in the wind turbine industry. Since then, we have evolved into over a dozen strong teams serving production lines across 5 continents.

We have maintained our commitment to designing and supplying the industry with precision tooling, pattern making and mold making over the years and will strive to always deliver the best for the most demanding audiences. We will maintain our focus on quality and delivery to meet every requirement of our customers.

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COMPLETED PROJECTS

High quality production tooling design & manufacture at our strategically located partners facilities.

Blade know-how, skilled labour and scalable footprint to enable blade prototyping.

Competitive and novel blade engineering solutions for global OEMs.

FERAS YOSEF FOUNDER

Having graduated from Imperial College with MSC/DIC in Composites Materials, Feras has spent 9 years working for the largest Wind Turbine Company in the world, where he was employed as Blades Tooling Specialist and the Tech Lead for blades lifting & assembly within blade production engineering business unit. During his time in the wind industry, Feras has successfully led the development, design, manufacture and commissioning of more than 15 serial production lines of blade shells, internals, lifting and assemblies in Denmark, Spain, Italy, UK, USA, China, Germany and Brazil.

The highlight of Feras’s career was being the lead tooling engineer and project manager on one of the largest blade shell moulds in the world. At +80m long, +70tonnes in weight, it was the first ever serial production shell mould in the world equipped with double-hinge technology and reduced turning height. The mould is currently operational in Europe.

I believe that Blades tooling is still a young industry, and there is globally a strong demand for reliable mould suppliers, that can deliver technically robust moulds at competitive prices. CAPEX and OPEX reductions are key to all blades manufacturers and have a direct effect on the cost of energy. Habitually, tooling requirements specifications do not exist or are over complicated, which to some extent increase the cost of the moulds. Good understanding of product design, and manufacture process is fundamental to the delivery of a good mould. At DFS Composites, we do not copy paste, we follow a six sigma approach to gather the voice of the customers which we translate into customer’s requirements specifications, which subsequently initiate our design phase.

OUR
TEAM

Our team is dedicated to delivering innovative solutions through a blend of creativity and technical expertise. We leverage cutting-edge technology and streamlined processes to transform ideas into high-quality products.

Comprised of experienced engineers, designers and manufacturers who work collaboratively to ensure that each project meets rigorous quality standards and customer specifications. Our strength lies in our ability to design and build products to specification.

The Tooling Service team is synonymous with efficiency, mobility, and competence. With a highly skilled team, we are prepared to operate in a variety of environments, always delivering agile and precise solutions.

Our commitment goes beyond simply providing services: we work with agility, safety, and precision, ensuring that every project is executed with excellence. With advanced technical expertise and a keen eye for innovation, we are always ready to offer support wherever and whenever needed.
No matter the location or requirement, our team is always ready for the job!

Expertise

Diverse skill sets in composites, mechanical, electrical, hydraulic and software engineering

Innovation

Commitment to research and development for continuos improvement.

Quality Assurance

Rigorous testing and validation protocols at each stage of production - Six Sigma and APQP4Wind

Customer Focus

Diverse skill sets in composites, mechanical, electrical, hydraulic and software engineering

WHERE
WE ARE

United Kingdom

Headquarter
Engineering & Desing Centre
Prototype & Manufacturing
5Axsis CNC Milling Centre

China

Supply-Chain Management Installation & Service

India

Engineering & Design Office Manufacturing & Fabrication Installation & Service

Mexico

Large Scale Manufacturing      5Axis Milling Centre    Engineering & Design Office Installation & Service

USA & Canada

Operation & Sales        Installation & Service