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Lightweight construction/composites

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.

Technology

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.

More speed in pultrusion: further development of the pultrusion process offers more productivity and efficiency for straight and bent profiles.

Benefits

  • Maximum flexibility and cost-effectiveness
  • Cost savings at high part quality
  • Low mold investments

Products

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Operating area

  • The feed-in area is designed to be extremely ergonomic and provides an equally excellent setup for an automated feed unit.
  • The majority of the waste in the operating area is collected in the available waste tray and fed to the central waste system inside the machine.
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Rotary double door / wall

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.

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Milling tool / spindle

  • KraussMaffei uses premium quality spindles and milling tools as its standard.
  • Milling tools 6 mm in diameter are used for normal cutting dimensions.
  • Generally, a smaller milling tool (d=2-3 mm) is used in the carrier for scoring airbags.
  • Optionally, a suction bell is available that extracts the chips right after the cutting process
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Visual representation with all production parameters

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12.1" Widescreen TFT display

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Option to run on a control cabinet

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Pentamix premixing station for pentane

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Perfect metering

  • Axial piston metering pumps with magnetic coupling adapted to polyurethane and reactive systems
  • Selection of various pump sizes depending on the customer application and range of mixing heads
  • Precise and reliable metering
  • Significantly longer service life
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Ensure the process capability of the machine

  • Detection of process parameters using conventional sensors
  • Volume flow
  • Pressure
  • Temperature
  • Optional: Mass flow measuring
  • Optional, frequency-regulated drives as the basis for a closed loop system
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Proven tank design

  • A wide variety of available tank sizes
  • Double-walled agitator tank for constant component temperature
  • Tank temperature control using cartridge heaters
  • Tank with agitator and level monitoring
  • Option for connecting additional components
  • Extensive combinations with heat exchangers and temperature control systems possible
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Metering piston for abrasive fillers

  • Special, high-pressure type PFD metering piston for PU mixtures containing fillers
  • Selection of various piston sizes depending on the customer application and range of mixing heads
  • Precise and reliable metering
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Proven tank design

  • Double-walled tank for constant component temperature
  • Tank with agitator and level monitoring
  • Various agitator geometries for optimum distribution of fillers
  • A wide variety of tank sizes possible
  • Option for connecting additional components
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Hydraulic servo drive unit

  • Hydraulic servo control of the piston speed
  • Precise and reliable metering
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Proven tank design

  • Double-walled tank for constant component temperature
  • Tank with agitator and level monitoring
  • A wide variety of tank sizes possible
  • Various agitator geometries for optimum distribution of fillers
  • Option for connecting additional components
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Frequency-controlled high-pressure metering pump

  • Perfect metering - Isocyanate
  • Frequency-controlled axial piston metering pumps with magnetic coupling adapted to polyurethane and reactive systems
  • Selection of various pump sizes to match the customer application and range of mixing heads
  • Significantly longer service life
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Metering piston for abrasive fillers

  • Perfect metering – Polyol (discontinuous)
  • Special, high-pressure type PFD metering piston for PU mixtures containing fillers
  • Selection of various piston sizes to match the customer application and range of mixing heads
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Computer in control cabinet, display in control panel with SDL connection

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Optional system visualization possible through "open" programming tool

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15" (SVGA) keypad and touchscreen display

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Barrel station with piston pump, electric agitator and pneumatic lift

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Frequency-controlled KraussMaffei high-pressure metering pump (axial piston pump) with magnetic coupling

Perfect metering - Isocyanate

  • Frequency-controlled KraussMaffei axial piston metering pumps with magnetic coupling adapted to polyurethane and reactive systems
  • Selection of various pump sizes to match customer applications and a range of KraussMaffei mixing heads
  • Precise and reliable metering
  • Significantly longer service life
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Tandem piston unit for abrasive fillers

Perfect metering – Polyol (continuous)

  • Electric tandem piston unit suitable for polyurethane mixtures containing fillers
  • Selection of various piston sizes to match customer applications and a range of KraussMaffei mixing heads
  • Precise and reliable metering
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Proven tank design

  • Double-walled tank for constant component temperature
  • Tank with agitator and level monitoring
  • Various agitator geometries for optimum distribution of fillers
  • A wide variety of tank sizes possible
  • Option for connecting additional components
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Release agent unit

  • Release agent as a third component
  • Metering release agent right at the mixing head
  • Self-cleaning mixing head principle
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Enclosure for high-temperature components

  • Axial piston metering pumps with magnetic coupling adapted to epoxy and PU systems
  • Selection of various pump sizes depending on the customer application and range of mixing heads
  • Precise and reliable metering
  • Noticeably longer service life
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Recording process parameters

  • Ensuring the process capability of the machine
  • Using conventional sensors
  • Volume flow
  • Pressure
  • Temperature
  • Frequency-regulated drives as the basis for a closed loop system
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Container stations for preconditioning PU components

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Enclosure for high-temperature components

  • Special, high-pressure type PFD metering cylinder for PA mixtures containing fillers
  • Precise and reliable metering
  • Heating duct system for metering pistons, cylinder jackets and bases
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Release agent module

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MK 10-2 RTM linear mixing head

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Compact and space saving

  • Pump module with high-pressure metering pump (including magnetic coupling)
  • Positioning of the metering module directly next to the IMM mold clamping unit
  • Optimal line lengths for the lowest possible influence on the process from hose venting as well as temperature and pressure losses
  • Positioning all required assemblies in the vicinity of the mixing head for precise metering of small quantities
  • Axial piston metering pumps with magnetic coupling for PU and other reactive systems
  • Precise and reliable metering
  • Significantly increased service life
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Perfect stockkeeping and positioning

  • The supply module contains double-walled agitator tanks, daily tanks, feed pumps, mixing head hydraulics and the system control
  • The modular control concept makes it possible to connect two completely independent metering modules to one supply module
  • Connecting lines between the modules with an electric trace heating system ensure the correct temperature control
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CO2 nucleation in daily tank

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CO2 nucleation in buffer tank

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Measuring, controlling, regulating

  • Ensuring the process capability of the machine
  • Detection of process parameters using conventional sensors
  • Volume flow
  • Pressure
  • Temperature
  • Frequency-regulated drives as the basis for a closed loop system
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Exact metering of small output rates

  • Small, one-piece machine frame with vertical design
  • Axial piston metering pumps with magnetic coupling adapted to PU and reactive systems
  • Selection of pump sizes 4 and 8 l/min
  • Hybrid version possible (piston metering)
  • Precise and reliable metering
  • Significantly increased service life
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Perfect conditioning of small tank volumes

  • Tried-and-tested tank concept with double-walled agitator tank
  • Double-walled agitator tank for constant component temperature
  • Tank temperature control using mold temperature controllers
  • Tank with agitator and level monitoring
  • Option for connecting additional components
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Mixing PU components

  • High-pressure counterflow injection: Components are shot into a mixing chamber at high speeds where the speed energy is converted into mixing energy
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Wetting glass fibers

  • The flow-oriented geometry of the cleaning piston generates a hollow, hose-shaped material flow and ensures optimum wetting of the shortened glass fibers
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Chopping glass fiber rovings

  • Cutting unit with cutter roller and pressure roller
  • Service-friendly: optimum accessibility with easy cutter roller replacement
  • Adjustable fiber quantity and length
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MK 8/12-2KVV-F transfer mixing head

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MK 25P-5K-F linear mixing head

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Suitable for round or flat-fan nozzles

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Extension of the nozzle

Applications

Automotive
Attachments

Contact

KraussMaffei Technologies GmbH
Krauss-Maffei Str. 2,
80997 Munich

KraussMaffei Technologies GmbH
Bielefelder Str. 29,
49124 Harderberg

KraussMaffei Technologies GmbH
Heiligenstraße 75,
41751 Viersen

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