Manufacturing

The manufacturing method that is best suited to the production of a part is always chosen based on the shape of the part and the production volume. The production volume determine what kind of tools are profitable to invest in.

Composite parts are mainly composed of a reinforcing material, a matrix material (we mainly use epoxy resins) and possible fillers. We use 3D prints and urethane foams as fillers, among others.

Manufacturing methods used:

Wet lamination

In this manufacturing method, the reinforcing fibers are carefully laid in layers in the mold and moistened with liquid resin during the laying process. Excess resin and air can be removed from the part, for example using air removal rollers, vacuum or double-sided mold. The method is also well suited for small series and large parts. The advantage is very simple molds.

Vacuum injection

In this method, a one-sided mold is made for the part, into which the reinforcing fibers are placed and the resin is sucked into the mold using vacuum. The advantage over the previous method is a higher reinforcement content in the finished part.

RTM (Resin Transfer Moulding)

In this method, the part is manufactured in a closed mold into which the resin is fed using pressure. Depending on the part and its requirements, vacuum can be used to ensure that the fibers are wetted and that no pores remain in the part. The advantage is dimensionally accurate parts, all of which are mold surfaces, which means that the need for finishing is minimal.

 

Prepreg

This method achieves the best strength properties for the parts. The material used is fibers that are pre-impregnated with resin, this allows for an optimal reinforcement percentage. The method also allows for optimal orientation of the fibers, which helps in achieving strength. Disadvantages: expensive material and tools.

 

SMC

A manufacturing method that offers very fast production cycles. The normal curing time in the mold is less than 10 minutes. The parts are dimensionally accurate and have a good surface quality straight from the mold. The need for post-processing is minimal and the parts are well suited for painting and varnishing. We can manufacture parts with a surface area of up to 80x80cm using this method.

 

Materials used

Fasteners

• Carbon fiber
• Fiberglass
• Kevlar
• Natural fibers

Matrices

• Epoxy resins

Fillers

• PVC foam
• 3D-prints
• Urethane foams