High-tech fibers in various matrices: KraussMaffei dominates the entire range of lightweight constructions and composites. We plan and finish all systems throughout the process chain in-house.
Fiber Composite Spraying (FCS) is a very flexible process for short-run production. By pouring a combination of different PU layers, its possible to produce composite parts exactly matched to specific applications. The FCS process is ideal for high-strength, very rigid, large-format, visible parts required in small quantities. The process uses only a simple negative mold without a mold carrier.
Each different layer can be made completely or partially of compact or foamed material, with or without fiber reinforcement. This way, nearly any wall thickness can be created. Only one mold-half is necessary. The surfaces of the medium-sized or large parts can be finished with a thermoformed film or using IMP (In Mold Painting).
In the LFI (Long Fiber Injection) process, endless fiber from a roving is chopped to length in a cutter. A blower then separates the filaments. Immediately after the cutter, the fibers are wetted with the PU mixture from the mixing head.
In R-RIM, short reinforcing fibers (glass, carbon, wollastonite) or fillers are added to the polyol component before processing. The PU mixture is poured into the closed mold, where it cures quickly.
For the C-RTM process (compression resin transfer molding), the resin mixture is fed into the mold when it is slightly open instead of closed. Thus the mold is not completely closed during the feeding. Consequently, the preform is already partially saturated by resin. The feeding is followed by a compression stroke, which presses the resin through the preform, causing it to become completely saturated.
In HP-RTM (High-Pressure Resin Transfer Molding) process, the first step is building up a fiber preform. A very low-viscosity, reactive resin is injected into the cavity at high pressure ensuring that each individual fiber is wetted and that there are not any air voids.
The newly developed surface resin transfer molding process enables cost-effective manufacturing of paintable fiber-reinforced visible components for vehicle manufacturing for series applications. That saves on time-consuming rework, which can amount to up to 60% of the costs per component.
Recycled fiber mats can be used in the wet molding process. The manufacturing process for the fiber mats can reuse materials such as the waste product from cutting fiber mats made of continuous fibers. This involves binding the individual fibers and forming them into mats again. However, the fibers are no longer aligned, but instead statically distributed. The flow resistance would be extremely high for impregnation in a closed mold, which is why the resin is added outside of the mold.
In the structural component spraying (SCS) processes, layers made up of fiber mats and honeycomb cores are sprayed with unreinforced PU, inserted into a mold and compression molded. This further development of LFI/honeycomb technology reduces the thickness and weight of the cover layers to further optimize the lightweight construction.
First a sandwich structure is made by putting the fiber mats on both sides of the honeycomb core. The sandwich is then sprayed with PU on both sides. Next the frame holding the sprayed sandwich is inserted into the mold, which is then shut. The fiber matting is saturated with polyurethane during compression molding and sticks to the core during curing.
Our RoutingStar milling machine is equipped standard with rotary double doors in the front operating area. The large acrylic windows provide a wide vantage point of the current status of workpiece holder in the operating area. The rotary wall of the machine rotates vertically and consists of two large holder areas.
Perfect metering - Isocyanate
Perfect metering – Polyol (continuous)