The development of flexible formwork has made it possible to cast optimised geometrically complex and thin walled reinforced concrete structures. At the same time, advanced composite materials offer the opportunity to solve the problem of steel corrosion, which can affect aging of concrete structures. With the goal of achieving sustainable design, being able to combine optimised geometries with durable construction materials is a major challenge for civil engineering. New research at the University of Bath and the University of Miami aims to completely replace internal steel reinforcement in geometrically complex concrete structures with durable and ready-to-use cages made of fibre reinforced polymer (FRP) reinforcement. By fabricating the reinforcement in the desired geometry, it will be possible to provide the required strength exactly where needed, thereby reducing the amount of concrete required to resist internal forces and capitalizing on the extraordinary possibilities offered by both concrete and FRP construction materials. The design of such optimized elements and the automated process of manufacturing the Wound FRP (W-FRP) reinforcement are presented in this paper.