Large series production of fiber-reinforced plastic components

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  • Combination of LFI & R-RIM processes for large components
  • FiberForm combines thermoforming and injection molding in one process
  • KraussMaffei at #JECEurope2015

As one of the few suppliers on the market, KraussMaffei is in a position to offer injection molding and reaction process machinery for the processing of thermoplastic and thermoset matrix systems from a single source. The company will present such systems for large series production of fiber-reinforced plastic components (FRP) at the #JECEurope2015

Combination of LFI and R-RIM processes for large components

Large components with immediately paintable surfaces for trucks and agricultural machines can be manufactured, for example, using the LFI (long fiber injection) process in combination with the R-RIM process (reinforced reaction injection molding). R-RIM is the only process for polyurethane fiber composite applications where the reinforcement material is contained directly in one component. It features a high degree of automation and, therefore, short cycle times. The low viscosity of the components makes it possible to manufacture large, complex, thin-walled, high-strength parts. These applications feature high temperature stability and very good impact strength and already have paintable surfaces. At #JECEurope2015, the company is presenting a fender for agricultural machines from Parat.

Immediately paintable: The LFI process in combination with the R-RIM process makes it possible to manufacture large, thin-walled components for trucks and agricultural machines

Immediately paintable: The LFI process in combination with the R-RIM process makes it possible to manufacture large, thin-walled components for trucks and agricultural machines

FiberForm combines thermoforming and injection molding in one process

The FiberForm process combines the thermoforming of composite sheets and injection molding in one process. The strength level of fiber-reinforced plastic components is increased through this procedure. The fully automated process enables short cycle times of less than 60 seconds and, therefore, production processes that are ready for large series. To date, FiberForm has been predominately used in the automotive industry to produce, for example, seat shells and backrests in series production. Whether extra stiffness through adding ribs, shaped openings with a reinforced edge or complex geometries, the process can be used to produce many things that would be nearly impossible as a sheet metal part. At #JECEurope2015, KraussMaffei is presenting infotainment holders developed jointly for Audi with partners Audi, Lanxess and Christian Karl Siebenwurst.

FiberForm rides along: the multi-function stringer in the new Kingpin touring ski binding from Völkl features high function and safety, while maintaining a low weight at the same time

FiberForm rides along: the multi-function stringer in the new Kingpin touring ski binding from Völkl features high function and safety, while maintaining a low weight at the same time

The product range of FiberForm is not just limited to applications in vehicle manufacturing. The most recent example, which can also be seen in Paris, is a multi-function stringer in the new Kingpin touring ski binding from Völkl. The basic body is made up of composite sheet, which is molded with a fiber-reinforced plastic and provided with multiple function elements. On a small, narrow surface, the multi-function stringer contains three highly loaded function elements, all made from fiberglass-reinforced polyamide.

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