Composite

The superior properties of a fiber composite material are achieved only through the interaction of the two components. Two components thus result in three acting phases in the material: very tensile fibers, a relatively soft matrix that embeds them, and a boundary layer that connects the two components.

Materials

The basic combination possibilities for composites result from the material classification of materials into polymeric (plastics), metallic, ceramic and organic materials. Application-specific attempts are made to combine the various advantages of the individual materials in the final material and to exclude the disadvantages.

Materials used:

  • glass fiber (GFRP)
  • aramid fiber (AFRP)
  • carbon fiber (CFRP)
  • GFRP/CFRP hybrid
  • AFRP/CFRP hybrid
  • CFRP/EPDM
  • various sandwich systems
     

Processes

Fiber composite parts can be produced specifically for your requirements from the moulds and models we create:

Model and mold making Model and mold making

Once the mold or model has been designed, it is produced on 5-axis machines in our own plant, in the case of an aluminum mold.
If a laminated mold is used, the ureol or epoxy model is cut and glued as a positive model on the saw, and then manufactured on a 5-axis model milling machine according to CAD data. A composite mold is then produced from the manufactured model.

[Translate to Englisch:] Modell und Formenbau
Material trimming Material trimming

Based on the CAD model and a ply book, the processing is created and then the fabric is cut into 2D stacks on the CNC cutter. Pre-cut material, which needs to be stored in a cool place, is then stored pre-commissioned in a climatically monitored refrigerated container until it is used.
Of course, the fabric is batch-managed and assigned to the corresponding serial number with IT support.

[Translate to Englisch:] Materialbeschnitt
Laminating Laminating

In air-conditioned rooms, the molds based on the ply books are laid out with different fabrics, evacuated and prepared for the curing process.

[Translate to Englisch:] Laminieren
Prepreg autoclave Prepreg autoclave

Our autoclaves dispose of pressure, temperature and vacuum monitoring:

  • Ø 600 mm and 2 meters length
  • Ø 1500 mm and 3 meters length
  • Ø 2500 mm and 5 meters length
Melt core technology Melt core technology

Thanks to our 3D printers, we are able to produce the necessary soluble cores in-house or cast them ourselves from low-melting alloys. The cores are then wrapped with fabric and the component is cured in the autoclave. Thus, geometrically demanding hollow bodies, such as air ducts, can be produced.

Hand wet lamination Hand wet lamination

Hand laminating is used for smaller series, simpler component geometries and for mold making. For this purpose, the molds and components are laminated by hand and cured at room temperature.

Prepreg out of autoclave Prepreg out of autoclave

In series production, we also offer the production of parts in heated molds, specially adapted to your components.

Vacuum infusion Vacuum infusion

Using the vacuum infusion process, we first dry-fill the fibers and, in the case of a sandwich, also the core materials into the mold. Subsequently, we let the resin flow into the mold by means of a vacuum.

RTM RTM

For series parts, we use the RTM process in addition to the vacuum infusion. In contrast to the vacuum infusion process, the resin is additionally pressed into the mold with overpressure in order to achieve a better component quality.

Press technology Press technology

For series parts, presses can also be used to produce many parts from one mold within short cycle times. In the other processes described above, the mold cannot be used again immediately for a longer period due to the curing cycle.

Annealing - post curing Annealing - post curing

In special annealing furnaces, components that are subject to high-temperature applications are post-cured up to 340 degrees Celsius.

Manual and CNC component trimming Manual and CNC component trimming

The manual cutting of the components takes place on trimming tables equipped with a special suction. For more complex geometries or higher quantities, this occurs either wet or dry with self-designed and self-made milling devices on 5-axis CNC milling machines.

[Translate to Englisch:] Bauteilbeschnitt CNC
[Translate to Englisch:] Bauteilbeschnitt manuell
Assembly & surface finishing Assembly & surface finishing

Individual components are joined together to form assemblies by means of bonding devices and, if necessary, cut to size a second time. This is followed by quality inspection and the desired surface finishing.

[Translate to Englisch:] Montage & Oberflächenveredelung

Advantages

Give us the opportunity to bring you closer to the material of the future and integrate its enormous advantages into your project.

  • low weight
  • high tensile strength
  • X-ray transparency
  • resistance to chemicals
  • corrosion resistance
  • adaptable temperature resistance
  • very good damping properties
  • outstanding spring properties
  • no material fatigue
  • very low density (approx. 20 % of steel, 50 % of aluminum)

Manufacturing examples

Discretion is a matter of course for us!
Due to secrecy agreements and a natural, self-imposed duty of confidentiality, we are only allowed to show approved customer parts.

We would be pleased to convince you of our skills and production possibilities in a personal conversation.