Established in Italy, Beyonder® is the first European industrial platform dedicated to the production of thermoformed components for OEM (Original Equipment Manufacturer) automotive applications. It is based on a fully automated integrated thermoforming and foaming process, certified by an international patent, valid in 43 countries.

The project, led by entrepreneur Sandro Mantella, who has more than twenty years of experience in this sector, represents an evolution towards a scalable, replicable industrial model focused on global standardization.

At the heart of the Beyonder® infrastructure lies one of Europe’s most advanced thermoforming plants. This project was developed across two production lines – the first installed in 2022 and the second operational since 2025. These were designed to ensure precision, repeatability, high-volume output in reduced timeframes, use of recyclable materials, waste reduction, and full component traceability. Developed together with technology partner Self Group Comi, the entire system was conceived from the beginning as a patented solution, encompassing its process, product, and construction details.

At the heart of the innovation is a proprietary process that combines ABS sheet thermoforming, precision trimming, and polyurethane foaming, enabling fully automated production of integrated plastic-and-insulation KITS ready for installation. Beyonder® is currently the first industrial system of its kind in Europe, the only one protected by a patent extended across 43 countries, and the only solution capable of achieving a thermal transmittance coefficient of 0.3 W/m²K for the complete vehicle, supported by an officially filed homologation process.

Beyonder® ATP isothermal KITS represent a major advancement in temperature-controlled transport, delivering performance levels 25% higher than reinforced insulation standards, enhanced thermal efficiency, seamless edge-free surfaces, modular aesthetics, and full integration with the vehicle’s interior geometries. The system enables lower energy consumption, increased autonomy for electric vehicles, faster and standardized installation, as well as simplified distribution and assembly across global markets. Designed as a fully Plug & Play platform, Beyonder® meets the evolving needs of fleets, converters, and vehicle manufacturers worldwide.

The technological foundation of the entire project lies in the production of thermoformed ABS panels for commercial vehicles, camper vans, and ambulances, engineered to deliver high thermal and mechanical resistance, anti-abrasion surfaces, process safety, and consistent quality standards. Building on this infrastructure, Beyonder® has developed a diversified range of KITS, tailored to a variety of application requirements and operational missions.

The Beyonder Insulation line offers high-performance isothermal KITS for temperature-controlled transport, available on a growing range of commercial vehicles from European and international brands. The first applications, already on the market since 2024, involve models such as Fiat Ducato, Peugeot Boxer, Citroën Jumper, Opel Movano, and Toyota Proace Max, with planned extensions until 2027 to Iveco Daily, Renault Master, Volkswagen Crafter, MAN TGE, and Fiat Scudo.

The Beyonder Protection line offers high-resistance ABS KITS for commercial vehicle protection, including Beyonder Protection Covers for LCVs, which are designed to ensure durability, lightness, ease of installation, and perfect integration with the vehicle structure. The solutions are available for a wide range of models from major European manufacturers, covering several Fiat, Peugeot, Citroën, Opel, and Toyota configurations.

Two additional lines are currently under development. First, Beyonder Healthcare will be dedicated to healthcare and medical vehicles, featuring continuous and easily sanitizable surfaces, chemical resistance, and optimal integration with internal geometries. Second, Beyonder Habitat is being designed for camper vans and motorhomes, with thermoformed solutions offering high insulation, mechanical resistance, and modular aesthetics.

Beyonder’s activities are carried out by a multidisciplinary team with automotive and aerospace expertise, engaged in the development of innovative materials, advanced chemical blend studies, and performance simulation, to industrialize highly specialized solutions while maintaining high-quality standards.

“Beyonder was created to industrialize thermoforming and turn it into a global standard,” says CEO Sandro Mantella. “We have developed a unique system that allows us to produce ready-to-install KITS that can be replicated anywhere, with performance levels never achieved before. Our goal is clear: to become the European benchmark for OEM thermoformed components.”

In a market increasingly focused on efficiency, sustainability, and industrialization, Beyonder® introduces a model grounded on intelligent standardization and global scalability, positioning itself as a new benchmark player in the European landscape. The brand’s vision is aimed at building a European distribution network, expanding product ranges, and consolidating its role as the leading European manufacturer of thermoformed components for the OEM market.

For more information:
www.beyonder.it – info@beyonder.it  – mob. +39 335 7301308