The toolmaker Siebenwurst uses injection molding simulation to optimize part design and production processes in its routine workflows. Among other things, Simcon’s software ensures the quality and dimensional accuracy of the plastic frame for the first series-produced injection molded e-bike.

The frames give the e-bikes an extraordinary design, with robustness comparable to steel or aluminum

Controlling Complex Development and Manufacturing Processes, Using Simulation

Spritzgießen

Kunststoffverarbeitung: Verfahren

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Verbundwerkstoffe / Werkstoffverbunde

Kunststoff Werkstoffe

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Spritzgießsimulation

Software

Simulation

A Bike Frame from an Injection  Molding Machine

Composite materials are often the key to lightweight design for many applications. However, these hybrid materials face a major challenge where recycling is concerned.

The experimental components were manufactured in a fully automated SMC manufacturing cell, developed by Engel, with an Engel v-duo 700 machine and an easix KR35 articulated robot

A Research Project Highlights the Recycling Potential of Lightweight Composites

Kohlenstofffasern / -matten

Verstärkungsstoffe

Anlagen zur Composite-Herstellung

Spritzprägen

Bruchmechanische Prüfung

Messtechnik

Werkstoffprüfung

Harzsysteme für Composite-Herstellung

UD-Tapes

Presswerkzeuge, Kunststoff

Pressen von Kunststoffen

Faserverbundwerkstoffe

Andere Werkstoffe

Kunststoff-Recycling

Kunststoff-Aufbereitung

Qualitätssicherung Kunststoff

Qualitätssicherung

Zero-Waste Concept for Carbon SMC

Climate change and the transport revolution are demanding smart fiber-reinforced composite solutions. In sectors such as the marine industry, infrastructure, and rail vehicle construction, many different fire protection concepts are competing. The composites industry is paying increased attention to recycling.

The first natural fiber-reinforced satellite panel permits safe space exploration and completely burns up on re-entry into the earth’s atmosphere

16:9

20:7

Fiber-Reinforced Composites Drive Innovation in the Transport and Construction Sectors

Glasfasern / -matten

Sekundärfasern

Kunststoff-Rezyklat

Fasern

Faserverarbeitung

Composites Are Trendsetters in Lightweight Design

Continuous fiber-reinforced thermoplastic composites have also become established with thin-walled housings for consumer electronics and information technology. Not only do they offer high stiffness and help to reduce weight, but also enable the integration of classy appearance and functions. What is more, if the housings are produced using the hybrid molding process, costs, processing steps, and cycle times can be reduced.

The Carbon 1 Mark II smartphone from Carbon Mobile was developed in Germany. The matt-black carbon fibers lend the smartphone a classy high-tech look

Composites Reduce Weight and Simplify Production of Electronics Housings

Kunststoff

Bauwesen

Baustoffe

Kunststofffasern

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Lightweight to Fit in a Pocket

As a result of the Corona crisis, press manufacturer Wickert sees only a temporary slowdown in the growth forecasts for composite technologies. The company currently sees four trends in system engineering.

Composite press for research: for scientists at the Chemnitz University of Technology, Wickert developed a highly flexible four-column upper piston press which offers a high level of freedom and diversity in application

The Demand for Composites Will Keep Growing in the Future

Pressen

Maschinen für die spanlose Fertigung

Duroplaste

Automatisierungstechnik

Hochleistungskunststoffe

Thermoplaste

Naturmaterialien

Trends in Composite Manufacturing

Thanks to a combination of polylactic acid and flax fabrics, Lanxess launches a full biocomposite in the Tepex range of continuous fiber-reinforced thermoplastic composites.

Demonstrator component with polylactic acid matrix and fabric reinforcement based on flax fibers. The component surface features a brownish bio-carbon appearance, which originates from the flax fibers

Biological and Suitable for Many Applications

As the long-awaited event of the global composites community, JEC World 2022 in May will bring together professionals from all backgrounds, eager to meet again in person.

JEC World 2022 in May will bring together professionals from all backgrounds, eager to meet again in person

The Global Composites Community Reunites in Paris

Tapes must be stacked both with high accuracy and efficiency. In the ongoing development of its tape-stacking cell, Engel places a third focus on simplifying operation. CAD-based tape stacking, which Engel has implemented in a customer’s system for the first time, will play a role here. Further new features are the pyrolysis function for cleaning the welding elements, as well as the modular end-of-arm tooling for handling the semi-finished products.

The new modular end-of-arm tooling of the tape stacking cell increases both the cost effectiveness and the flexibility. The functional elements can be individually positioned thanks to a perforated grid.

CAD-Based Tape -Stacking

Bildverarbeitungssysteme

Fertigungsautomation

Bildverarbeitung

Industrieroboter

Montagetechnik

Greifer für die Kunststofftechnik

Handling, Handhabungstechnik

Precise but Highly Efficient

JEC World 2022 will take place from May 03 to 05 in Paris Nord Villepinte with an interesting conference program.

The conferences program will be available for free to all registered participants, in two Agoras (Hall 5 and Hall 6) and also online via JEC World Connect.

Conferences Program

The battery system is one of the heaviest components in the powertrain of an electric vehicle. The use of lightweight materials and high-volume production processes according to requirements and functionality offers significant potential to reduce weight without compromising on safety or performance. A new technology concept shows the particular advantages of using a modified direct process with a tailored material selection.

Lightweight battery module with lithium-ion battery cells in pouch cell format and SMC module end plates.

Lightweight Traction Battery System for Electromobility

Elektromobilität

Mobilität

Leichtbau

Polyurethan

Energiespeichersysteme

Lightweight Construction  for Heavyweights

Particularly two industries have shown considerable interest in FPP technology: aerospace industry in automating the lay-up processes of multi-material lightweight components with sandwich cores, as well as manufacturers of CFRP pressure vessels for hydrogen-powered vehicles (FCEVs), who can thus achieve savings in the double-digit percentage range. In both areas, FPP is the first technology to automate critical fiber lay-up processes in order to industrialize the production.

Laminate reinforcement of filament-wound pressure tanks. The shape of the patches and the gripper is adapted to the size and complexity  of the component.

New Applications for the Automated Production of Fiber Composite Components

Greifer

Inspektionssysteme

Reinforcement on Approach

Temperature tolerence, force density, pressure setting: requirements for press technology

Ballistic panels are being used as armor for civilian and military vehicles, ships and aircraft. The image shows a test blast to demonstrate the safety for vehicle occupants.

Pressing of Ballistic Panels Made of Fiber-Reinforced Plastics

Safety First

Röchling is taking over the Swiss SMC specialist Compotech, thereby expanding its product portfolio with large-format compression molded parts.

Röchling is taking over the SMC specialist Compotech AG in Weinfelden, Switzerland, with retroactive effect from January 1, 2023, thereby expanding its product portfolio with large-format compression molded parts, in particular for railway technology.

Compotech specializes in the manufacture of molded parts made from glass fiber reinforced plastic. The large-format parts, which are mainly manufactured using the SMC pressing process, are machined further on CNC machining centers, and then painted, glued and assembled. The products made of fiber composite materials are used throughout Europe in areas such as transport, mechanical and apparatus engineering, medical technology, electrical engineering, and the sanitary sector.

Röchling integrates the activities of Compotech AG into the product line Composites of the Röchling Industrial Division, which, with production sites in Haren/Germany, Nancy/France and Cleveland/USA, is one of the leading manufacturers of composite materials in a large number of industrial sectors worldwide.

Uwe Kassens, who is responsible for the composites business at Röchling Industrial, is looking forward to the integration: „Compotech has an excellent reputation in the market. Our particular interest was aroused by the competence of the highly qualified employees in production, final assembly, and the logistics of complete assemblies. Compotech’s products and services fit perfectly with our existing activities and offer many synergies, not only in Europe.“

Röchling Industrial SE & Co. KG  

https://www.roechling.com/industrial

The integration also secures the continued existence of the Compotech site in Switzerland for the employees in the long term.

2023-03-30 Röchling Compatec

issue 04/2023

issue 03/2023

issue 02/2023

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