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Fiber Composite Solutions
 

Fiber Composite Solutions

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Fiber Composites for High Specs Light weight parts

Fiber Composites for High Specs Light weight parts

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    Fiber Composite Solutions Fiber Composite Solutions Document Transcript

    • FIBER COMPOSITE SOLUTIONSFOR HIGH SPEC,LIGHTWEIGHT PARTS
    • PROCESSES FIBER COMPOSITE SOLUTIONS Material properties Part and process specifications Cost PORTFOLIO factors pe nt/ ure g y ns ity/ sin etr em sista rat ion me ex abil es om el tin e re roc olu lev l st ty /Ge pa ali nv ab ld p y at erm na era ur on ilit ity gt qu orm Op erat tio Th sio ati y sab lex cap mo al ilit PROCESSES ONE PARTNER – MULTIPLE SOLUTIONS ce uc tom en e/F mp mp st- rfa es od Dim Str Siz Po Au Co Su Pr TeProcesses IM-SGF Injection molding, Page 6 WHATEVER YOUR CHALLENGE, PROCESS EXPERTISE AND ENGINEERING short fiber reinforcement WE HAVE A SOLUTION KNOW-HOW Four main factors determine the properties of a Our wide experience is at your service throughout molded part. They also limit the manufacturing your product development project – from the first IM-LGF Injection molding, Page 6 processes that can be used: idea through prototyping to mass production. long fiber reinforcement – Reinforcing fibers, type and length This close cooperation and harmonizing of pro- – Plastic matrix duct and process is a guarantee of successful – Part geometry outcomes. IMC – Production volume Injection Molding Page 8 Compounder Our engineers have unique know-how across all MANUFACTURING EXPERTISE aspects of plastics processing. We supply not IN FIBER COMPOSITES only machinery and processes, but also molds FiberForm KraussMaffei has worked for many years on pro- and tooling, as well as systems for post-mold Shaping and encapsulating Page 10 organic sheet cesses for manufacturing parts made of fiber-re- processing and product testing. With this wide inforced plastic (FRP). The new processes evolved product and service portfolio, KraussMaffei is from traditional injection molding or polyurethane your ideal partner for your entire development Polyset BMC/SMC (PU) molding. Today our process portfolio ranges and implementation process. Injection molding Page 12 from injection molding resin with short glassfiber polyester BMC/SMC reinforcement to high-strength, lightweight parts CHECK OUT WHAT KRAUSSMAFFEI with a complex fabric structure in a reactive matrix. CAN OFFER YOU! R-RIM Paging through this brochure will give you some Reinforced Reaction Page 14 We set the highest priority on manufacturing pro- idea of the scope of our machinery, processes Injection Molding cesses that are automation-capable. and services. Consult us about your next project; it’s a challenge we will welcome! And you can be FCS sure of our support from start to finish. Fiber Composite Page 16 Spraying LFI Long Fiber Page 18 Injection SCS Structural Component Page 20 Spraying HP-RTM High-Pressure Resin Page 22 Transfer MoldingOptions CellForm (MuCellTM) Page 24 IMP In Mold Page 25 Painting Excellent very good Good
    • PORTFOLIO MACHINE OvERvIEWPORTFOLIOONE EXPERT PARTNER FOR YOURENTIRE VALUE-ADDING PROJECT MACHINE OVERVIEW Twin-screw extruders, Processors compounding their own formulations have a choice of two extruder series, each with 13 output categories The ZE-UTX/UT series screws and barrels of the two ZE series (ZE-A and ZE-R) have been engineered with identical axis distances for full inter- Twin-screw extruders, ZE-UTX/UT series Whatever you aim to achieve in plastics or changeability to simplify upgrading for new production tasks. Modular engineering means that the screws can be configured Compounding rubber processing, KraussMaffei is your and reconfigured to process different formulations on one and the same extruder. partner. We are the only company with All-electric injection Our AX series covers a broad product spectrum and application range. The AX series gives you flexibility, stable processes intensive expertise across the three main All-electric injection molding machines molding machines (50 to and the assurance of low unit manufacturing costs. engineering fields. And we have a strong 350 t), AX series (50 to 350 t), AX series track record in integrating this expertise to Injection molding develop new processes and systems. All-electric injection EX machines have been engineered uncompromisingly on the principle of direct transfer of force. The Z-toggle clamp and All-electric injection molding machines READY FOR ANY CHALLENGE molding machines (50 to the direct-drive injection unit exemplify the strengths of all EX machines – outstanding precision, ultra-fast responses and 240 t), EX series absolute cleanliness. The high-performance, high-precision EX machines turn in the fastest dry cycle times in the industry. (50 to 240 t), EX series KraussMaffei’s Injection Molding Machi- Injection molding nery Division engineers and supplies sys- tems, including automation solutions, for CX modular platform The CX series of hydraulic injection molding machines feature a 2-platen clamp design. The ultimate in modular engineering, The CX modular platform – hydraulic standard applications and for almost all - hydraulic and hybrid in- the CX series offers over 100 clamp/injection unit combinations and over 500 options, making it possible to configure efficient, jection molding machines application-specific, high-performance machines. CX machines are the perfect starting point for today’s technology variants – from and hybrid (35 to 650 t) processing variants. Our main markets - 35 to 650 t processing thermosets to multicomponent molding to foam processes. Injection molding are in the automotive, packaging, electri- cal, electronics, medical technology and Big, all-hydraulic injection MX machines are engineered to deliver sustained performance under demanding conditions. For all their size, they are Big, all-hydraulic injection molding machines consumer goods industries. molding machines (850 to compact, high-performance production systems, featuring fast responses, fast cycles and high productivity. versatile and 4000 t), MX series modular, they offer a wide range of solutions, especially for large-format parts. (850 to 4000 t), MX series Injection molding In reaction process machinery, we engi- neer and supply machines and systems LRX and IR series of We offer machine-specific automation solutions using LRX or IR series robots for all our machine ranges. Robots are supplied with for processing polyurethanes and other LRX and IR series of linear and industri- linear and industrial fully integrated or stand-alone control systems. Integrating standard components, such as conveyor belts and safety gating, we are in al robots reactive materials. Tooling Technologies robots a position to supply cost-competitive, CE-compliant manufacturing cells with very short order lead times. Our product portfolio also includes specialties, such as tandem robots for linear robot applications or a 7th axis for industrial robots. Production automation supplies a complete range of molds and tooling, cutters and routers. Our cus- Global players – the The RimStar MiniDos, Compact and Modular series offer optimal mixing and metering solutions for every type of PU proces- tomer base is wide, with a focus on the RimStar series sing. Modular engineering and flexible machine configurations mean that RimStar covers the whole spectrum of PU proces- Global players – the RimStar series automotive, construction and the white ses. The RimStar Thermo version is engineered to process epoxy resins and serve as a metering unit for RTM processes. Polyurethane processing – wet side appliances industries. Metering filled multiple- Comet is a range of piston metering machines engineered to meter PU components with abrasive fillers, such as glass fibers The Extrusion Division supplies machine- Metering filled multiple-component reactive component reactive or wollastonite. The machines have metering pistons instead of pumps. The abrasive fillers can be added to both the polyol ry and systems for compounding, and for systems with the Comet and the isocyanate component. systems with the Comet series pipe, profile, film and sheet extrusion, for series Polyurethane processing – wet side physical foaming, and for the production High-pressure mixing The mixing head is the heart of a polyurethane processing system. High shot rates, good product quality and highest produc- of technical rubber products and inter- heads for all PU proces- tivity are a direct outcome of our many decades of experience and our commitment to continuous improvement of the whole High-pressure mixing heads for mediates for tire production. Products sing applications range of KraussMaffei mixing heads. Our mixing head portfolio ranges from linear mixing heads to multicolor, transfer and all PU processing applications from the company’s range – from single filler mixing heads. extruders to complete extrusion lines – are used in industries as diverse as che- Mold carriers – from Based on standardized modules, KraussMaffei supplies mold carriers with optimal mold closing for almost any application. standard to special A range of drive and closing concepts deliver the optimal combination of dynamics and efficiency. In addition to a choice of Mold carriers – from standard to special micals and automotive, pharmaceuticals, standard formats, KraussMaffei is also a successful project partner for complex custom solutions. Polyurethane processing – dry side construction, furniture and packaging. Expertise in foam, RIM, KraussMaffei supplies molds and tooling for all processes, including casting, foaming and back foaming. Each molds is a Expertise in foam, RIM, CCM, LFI and CCM, LFI and special custom design, application-specific and optimized for the specific production process. We supply steel, aluminum and resin molds molds, together with post processing equipment, such as milling machines and punches. special molds Routers and punches Complete downstream Our complete portfolio of PU processing machinery includes fully- and semi-automated processing cells for trimming, Complete downstream and system solutions and system solutions punching and routing PU moldings. Our profound, wide-ranging expertise in tooling enables us to supply complete manufac- turing lines engineered for fast processing, reduced waste and optimized swarf removal. Routing and punching systems including tooling
    • 2 FIBER COMPOSITE SOLUTIONS CONTENTS 3 CORE COMPETENCE MANUFACTURING SYSTEMS FOR LIGHTWEIGHT FIBER COMPOSITES – OUR CORE COMPETENCE CONTENTS PAGE In many sectors, such as automotive and PROCESSES IN OVERVIEW ��������������������������������������������������� Front cover commercial vehicle manufacturing, compo- APPLICATIONS ����������������������������������������������������������������������������������� 4 nent specifications have escalated in recent INJECTION MOLDING WITH SHORT- OR LONG-FIBER-REINFORCED PELLETS ������������������������������������������� 6 years. Typical demands are for higher me- IMC – INJECTION MOLDING COMPOuNDER ��������������������������������������� 8 chanical strength and lighter weight. FIBERFORM – THERMOFORMING ORGANIC SHEET PLuS INJECTION MOLDING �������������������������������������������������� 10 We have the machine portfolio, the wide POLYSET – INJECTION MOLDING POLYESTER MOLDING COMPOuNDS ������������������������������������������������������������������� 12 process know-how and the inherent grasp of R-RIM – REINFORCED REACTION INJECTION MOLDING ������������������ 14 potential along the value-adding chain which FCS – FIBER COMPOSITE SPRAYING ������������������������������������������������ 16 enable us to supply efficient, highly automated, LFI – LONG FIBER INJECTION MOLDING multiprocess solutions for manufacturing fiber WITH REACTIVE Pu �������������������������������������������������������������������������� 18 composite parts. SCS – STRuCTuRAL COMPONENT SPRAYING WITH REACTIVE Pu �������������������������������������������������������������������������� 20 HP-RTM – HIGH-PRESSuRE You’ll find that KraussMaffei is, in fact, uniquely RESIN TRANSFER MOLDING ������������������������������������������������������������ 22 positioned to deliver the very best match CELLFORM (MuCELL TM) ��������������������������������������������������������������������� 24 between manufacturing technology and your IMP – IN MOLD PAINTING ����������������������������������������������������������������� 25 part specifications and target volumes. We are CONSuLTING – TESTING – IMPLEMENTATION ��������������������������������� 26 your expert partners at all times – from your TECHCENTER FOR INJECTION AND REACTION MOLDING ��������������� 27 product idea through to a successful manufac- Pu TOOLING TECHNOLOGIES ����������������������������������������������������������� 28 turing solution. DEVELOPMENT SuPPORT ���������������������������������������������������������������� 29 SERVICE WORLDWIDE ��������������������������������������������������������������������� 30 MACHINE OVERVIEW ����������������������������������������������������������� Back cover
    • 4 FIBER COMPOSITE SOLUTIONS APPLICATIONS MOBILITY, ENERGY, ENVIRONMENT, LIGHTWEIGHT – WITH PRODUCTION SOLUTIONS FROM KRAUSSMAFFEI AVIATION IM-S GF Fib er Fo rm LF I HP -R TM SPORTS GF IM-S F -LG SHIP BUILDING RAIL TRANSPORT IM m r GF Fo IM-S er TM IMC b Fi rm FC S -R Fibe HP lFo rFo I LF rm Cel M Po lys -RT SC et BM CAR MAKING HP S C/S MC IM-SGF HP WIND POWER GF -R IM-L TM FCS IMC rm M Fo -RT er C HP Fib SM C/ M BM RI I LF et R- S lys SC RTM Po CellForm AGRICULTURAL MACHINERY HP- IM-SGF GF IM-L IMC COMMERCIAL VEHICLES r m Fo IM-SGF er C Fib SM C/ IM-L M GF BM RI S t IMC R- FC se LFI ly SCS Fib HP-RTM CellForm Po er Po Fo lys rm et R- BM RI FC C/ M SM LF S SCS C HP-RT CellForm I M MANY USES FOR FIBER COMPOSITES ENDLESS POTENTIAL BREAKTHROUGH WITH AUTOMATED PROCESSES Components made of fiber-reinforced plastics (FRP) play The length and orientation of the reinforcing fibers to- Producing successful products on an industrial scale ment industrial-scale production solutions for fiber composite an essential role in many aspects of modern life. Fiber gether with the chosen resin matrix are responsible for the demands more than just good product properties� The keys products� We supply automated solutions which take account composites are a fast-growing field because they offer an property profile of the finished part. We offer a wide range to success are automated and repeatable manufacturing not only of product quality but also production volumes� This unsurpassed mix of benefits, chief among them are high of engineering solutions and processes to manufacture fi- processes� With our intensive know-how in machinery, meets the basic requirement for the growing use of FRP in mechanical strength and very low weight. ber composite parts, the final choice will depend on factors processes and tooling for reaction processes and injection volume models in the automotive industry� such as part size and specifications. molding, KraussMaffei has the tools to engineer and imple-
    • 6 FIBER COMPOSITE SOLuTIONS PROCESSES INJECTION MOLDING SHORT- AND LONGFIBER-REINFORCED THERMOPLASTICS 7 INJECTION MOLDING SHORT- AND LONGFIBER-REINFORCED THERMOPLASTICS A NEW APPROACH TO A FAMILIAR, STANDARD PROCESS INJECTION MOLDING WITH SHORT-FIBER IMPACT-RESISTANT COMPONENTS WITH LFT PROCESSES INJECTION MOLDING SHORT- AND LONGFIBER-REINFORCED THERMOPLASTICSIM-SGF ZE uTX REINFORCEMENT (IM-SGF) Adding short glass fibers to a resin matrix produces parts Thermoplastics are often reinforced with short fibers, usu- with high rigidity, strong enough to take higher loads� The Description Many thermoplastics can be reinforced with short glassfibers� The ready-compounded pel- ally glass fibers, to increase the stiffness and strength of same result can be achieved by adding longer fibers, but lets normally have a fiber content of 15 to 50 percent by weight� They are processed in stan- the molded part� The ready-compounded pellets normally because fewer fibers are needed the parts are lighter� LFT dard injection molding machines where the plasticizing unit has additional wear protection� AX seriesIM-LGF have a fiber content of 15 to 50 percent by weight� Materials with higher fiber content is typically used for non-visible By contrast, LFT with fiber/pellet lengths of 12-25 mm needs to be processed in machines used in series production of technical parts often have a semi-structural components, such as frontends and instru- with specially adapted screw geometries and usually also with an injection compounding fiber content of 60 percent and more� ment panels carriers� These components need high impact process that avoids damaging the long fibers� resistance in order to function despite impacts and vibra- EX seriesIMC The highly abrasive ends of the glass fibers stick out of the tions� LFT components inevitably have less oriented fibers, half-melted pellets and aggravate the wear on the plasti- because the long fibers tend to block each other� Features 1� Fully-automated standard injection molding machine, slightly modified cizing unit� KraussMaffei plasticizing units have a level of 2� Familiar processing method CX modular platform wear protection to match the application� This ensures that MULTIDISCIPLINARY KNOW-HOW FOR 3� Wide choice of materials from many different suppliersFiberForm process parameters remain constant over a longer service life� FIBER-REINFORCED PELLETS Pluspoints 1� Short cycle times and fully automated large-volume production We link up our know-how in material preparation and 2� Improved mechanical properties and high stiffness compared PROCESSING LONG-FIBER-REINFORCED PELLETS compounding plastics with our many years’ experience with unfilled resinsPolyset BMC/SMC (IM-LGF) in injection molding to deliver highly productive complete 3� Can be combined with almost any other injection molding variant MX series The use of thermoplastic pellets reinforced with long fibers solutions� To supply customers with solutions for the whole results in a significant improvement in the mechanical process chain we apply our extensive knowledge of pro- Typical applications Seat shells, instrument panel carriers, door modules, technical under-hood parts properties of the parts� The fiber length is matched to the cesses and applications and advanced engineering skills� Typical annual volumes 300,000 to 600,000 items length of the pellets, ie, it is 12 or 25 mm long� LFT pellets KraussMaffei solutions are the best possible match for cus- LRX/IR seriesR-RIM cost much more to manufacture than short-fiber pellets, tomers’ production requirements and for the formulations so it’s important that their length advantage and better they plan to process� Our colleagues in the extrusion divi- reinforcing performance are not destroyed by over-vigorous sion are experts in machinery for compounding resin with processing� reinforcing material and fillers, such as glassfiber, talcum, RimStar seriesFCS carbon fibers, calcium carbonate and barium sulfate� SPECIAL SCREWS AND COMPRESSION MOLDING During plasticizing, specially designed screws reduce the PRODUCTS FROM KRAUSSMAFFEI MACHINES unavoidable shear effects to avoid fibers snapping off and Comet series prevent excessive wear� Injection compression molding andLFI skillfully engineered mold geometry, especially for ribs, radii and hot runners, reduces damage to fibers during mold filling and pressure holding� Pu mixing headsSCSHP-RTM Pu dryside Part Transmission element BMW Part Door module and interior trim Mini Material PA 66 with 50 percent short glassfiber Material Decor: TPO film with flexible foam Substrate: PP with 10 percent long glassfiber Technology Standard injection molding with wear-protected Pu tooling plasticizing unit Technology Injection molding with fiber protecting screwCellForm Single-stage process (DecoForm), as TPO film is Benefits – Withstands high and oscillating mechanical loads; directly backfoamed highly temperature resistant – Wider design scope than with metal; acoustic Benefits – Highly cost-competitive, because it combines visi- damping ble parts and multifunctional parts with enhanced Pu trimming – Weighs 50 percent less than an equivalent metal part mechanical specificationsIMP
    • 8 FIBER COMPOSITE SOLuTIONS PROCESSES IMC – INJECTION MOLDING COMPOuNDER 9 IMC – INJECTION MOLDING COMPOUNDER IMC = COMPOUNDING + INJECTION MOLDING BIG COST SAVINGS IN MASS PRODUCTION ONE MACHINE TO MIX THE MATERIALS processed once (instead of cooling, storage and remelting, if PROCESSES DIRECT COMPOUNDING WITH THE IMC (D-LFT-IM)IM-SGF ZE UTX AND MOLD THE PART pellets are used) and they are fed into the melt in the direction The polymer matrix is first plasticized and mixed with addi- of processing� Description The IMC – Injection Molding Compounder – combines continuous compounding, typical of tives in a corotating twin-screw extruder� The reinforcing extrusion systems, with injection molding, which is a discontinuous process� It’s a cheaper fibers are fed into the extruder, wetted with the molten AUTOMATED AND FLEXIBLE FOR BIG SERIES method than using pellets for making longfiber-reinforced thermoplastic (LFT) parts and AX seriesIM-LGF thermoplastic, which naturally shortens them, and trans- The IMC process can be highly automated� Together with part properties are better� ferred to an injection piston� During the brief injection and other key benefits, this makes direct compounding the holding pressure phase, the compound, which is produced process of choice for producing big runs of fiber composite Features 1� Highly automated process continuously, is collected in a melt buffer� The continuous parts� The integrated control ensures that the formulation 2� Flexible adaptation to changing requirements EX seriesIMC melt process guarantees constant good material quality� and the material quality are constant and that the process 3� Compounding using low-cost standard raw materials is fully documented� Changes to the formulation are sim- Pluspoints 1� Short cycle times and fully automated large-volume production LOWER UNIT MANUFACTURING COSTS AND ple, so that the process can be adapted flexibly to meet 2� Long fibers for better material properties and high stiffness CX modular platform BETTER PRODUCT PROPERTIES different part specifications� The IMC system is just oneFiberForm 3� Lower material costs Direct compounding/injection with the IMC saves energy example of productive interdisciplinary collaboration at and material costs (0�3 to 1�0 €/kg cheaper than processing KraussMaffei – it successfully merges injection molding Typical applications Frontend carriers, transmission elements, front partitions, battery wells LFT pellets)� In consequence, it has widely replaced LFT in know-how with expertise in compounding and extrusion� Typical annual volumes 300,000 to 600,000 itemsPolyset BMC/SMC manufacturing semi-structural components� The mechanical MX series properties of the finished part are also better, because the process is less destructive of the fibers� The fibers are only LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES Melt buffer Weighing, metering and feed systems Comet seriesLFI Pu mixing headsSCSHP-RTM Transfer valve Pu dryside Part Carrier (frontend) Volkswagen Part Acoustic damping mats Shut-off nozzle Material PP-GF30, long fiber reinforcement Material PP EPDM filled with barium sulfate Technology IMC direct compounding with metal insert in up- Technology IMC direct compounding with filler Pu tooling per belt for energy distribution in an offset frontal Followed by application of Pu acoustic flexible foamCellForm collision Benefits – Low part weight through acoustic-defined wall Twin-screw extruder Benefits – As module carrier, multifunctional part; good thickness reduction energy absorption, esp� oscillation – Higher filler content and good homogeneity – Good impact resistance due to long fiber – No trimming waste Pu trimming reinforcementIMP – Very cost-competitive process for big series, as no intermediate cooling and remelting Shot pot injection unit
    • 10 FIBER COMPOSITE SOLuTIONS PROCESSES FIBERFORM – THERMOFORMING ORGANIC SHEET PLuS INJECTION MOLDING 11 FIBERFORM – THERMOFORMING ORGANIC SHEET PLUS INJECTION MOLDING THERMOFORMING ORGANIC SHEET PLUS INJECTION MOLDING FIBERFORM – MULTIFUNCTIONAL PROCESS HIGHLY-AUTOMATED MANUFACTURING CELLS PROCESSES FIBERFORM – THERMOFORMING AND BACK INJECTION OF ORGANIC SHEETIM-SGF ZE uTX To further improve the strength of fiber-composite injected Like standard injection molding, FiberForm can be easily parts, KraussMaffei combines injection molding with ther- automated� The outcome is compact, fully-automated Description Thermoforming of organic sheet and back injection with filled thermoplastic resin moforming organic sheet� Fabric made of endless fiber in manufacturing cells� a thermoplastic matrix is heated, shaped in the injection Features 1� Thermoplastic molded parts with endless fiber reinforcement AX seriesIM-LGF mold and then back injected� This process can be used to VERSATILE PROCESS 2� Highly automated and reproducible manufacturing process add ribs for extra stiffness and to integrate other functions� Like injection molding, FiberForm can be combined with 3� High functional integration as part of the injection molding process almost all special manufacturing processes� This opens up Pluspoints 1� No post-mold processing – final part contours in injection molding process FAST AND HIGHLY AUTOMATED infinite potential for functional integration and part design� 2� Short cycle times, typical of injection molding processes EX seriesIMC Cycle times are similar to typical values for injection mol- 3� Fully automated process ding (around 60 seconds) and are chiefly determined by the cooling time in the mold� The process can be seamlessly Typical applications Seat shells and backs, instrument panel carriers, box covers, side impact protection, CX modular platform integrated into an injection molding operation� In other words, technical under-hood components, semi-structural partsFiberForm FiberForm is ideal for manufacturing lightweight structural Typical annual volumes 250,000 to 400,000 items parts in big series�Polyset BMC/SMC MX series LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES 1. 2. Comet seriesLFI Pu mixing headsSCS 6. 3. 1� Pick up insert 2� Preheat insertHP-RTM 3� Transfer to mold Pu dryside 4� Thermoforming 5� Back injection Part Predevelopment project: door impact bar Audi A4 Part Predevelopment project: crossmember Audi A4 6� Remove from mold Material PA 6 GF60 + PA-GF 50-50 organic sheet Material PA 6 GF60 + PA-GF 50-50 organic sheet Technology FiberForm + formed bolt holes Technology FiberForm Pu toolingCellForm Benefits – High mechanical strength Benefits – Organic sheet is highly shapeable – Assembly-ready – Cost-competitive for big series – Short cycle times – High mechanical strength Pu trimmingIMP 5. 4.
    • 12 FIBER COMPOSITE SOLuTIONS PROCESSES POLYSET – INJECTION MOLDING POLYESTER MOLDING COMPOuND 13 POLYSET – INJECTION MOLDING POLYESTER MOLDING COMPOUNDS FULLY AUTOMATED PROCESSING OF BMC/SMC MOLDING COMPOUNDS With their very low viscosity, thermosets are highly suitable UNIQUE FEED SYSTEM – RELIABLE INJECTION PROCESSES POLYSET – CONTINUOUS INJECTION MOLDING OFIM-SGF ZE uTX for impregnating fibers to produce FRP parts. Because MOLDING PROCESS POLYESTER MOLDING COMPOUNDS (BMC, SMC) of their resistance to high temperatures, thermoset FRP The doughy material is removed from its packaging and parts are regularly used as substitutes for metals. Sheet placed directly, without interrupting the production cycle, Description PolySet – process for wet polyester molding compounds that are not free flowing, molding compound (SMC) and bulk molding compound into the feed hopper of an injection molding machine� The for small to medium series AX seriesIM-LGF (BMC) are used for very stiff, precision parts, which are rotating action of the hopper and the feed screw transports Features 1� unique feed method for continuous material transport regardless of the often painted. The very wide temperature resistance (from the material into the heated plasticizing unit� After injec- form or consistency of the wet polyester material low temperatures to 180 °C) and the option of in-line tion, the precisely metered thermoset cures in the hot mold 2� Robust construction, long service life even processing highly abrasive materials painting to achieve Class A surfaces result in a very broad to produce the finished part� EX series 3� Special, material-specific machine portfolio for thermosetsIMC application range. Pluspoints 1� Precision transport with closed-loop control of stuffing pressure, for constant processing conditions A RATHER DIFFERENT RAW MATERIAL 2� Refilling without interrupting process cycle CX modular platform The doughy polyester- or vinylester-based resins are 3� Outstanding homogenization, non-destructive processingFiberForm reinforced with glassfiber� BMC is reinforced with short Typical applications Valve covers, headlamp reflectors, oil sumps, ashtrays glassfiber, SMC with long glass fiber (25–50 mm)� The compounds are supplied ready-to-use� Typical annual volumes 200,000 to 300,000 itemsPolyset BMC/SMC MX series LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES Feed chute Comet seriesLFI Material hopper Pu mixing headsSCSHP-RTM Pu dryside Transducer Part Headlamp reflector, Mercedes Part Throttle valve housing Feed screw Material BMC – uP resin with short glass fibers; Material BMC – uP resin with short glass fibers LS setting for high dimensional accuracy Technology PolySet – injection molding BMC Pu tooling Technology PolySet – injection molding BMCCellForm Benefits – Minimal tolerances (0�02 mm) Benefits – Highly reproducible thanks to a well-monitored – Complex geometries with no post-mold process processing – Class A surface with post-mold painting – Operating range from -40°C to 150°C – Excellent dimensional stability over the whole – Good thermal insulation properties for winter use Pu trimming operating temperature rangeIMP Injection unit Injection piston Drive shaft
    • 14 FIBER COMPOSITE SOLuTIONS PROCESSES R-RIM – REINFORCED REACTION INJECTION MOLDING 15 R-RIM – REINFORCED REACTION INJECTION MOLDING PERFECT SURFACES FOR THIN-WALLED, FIBER COM- POSITE PARTS USING HIGHLY REACTIVE PU SYSTEMS In R-RIM, short reinforcing fibers (glass, carbon, wollas- VOLUME PARTS FOR INLINE PAINTING PROCESSES R-RIM PROCESSING FILLED POLYURETHANE COMPONENTSIM-SGF ZE uTX tonite) or fillers are added to the polyol component before The R-RIM process produces parts with excellent material processing. The PU mix is poured into the closed mold properties� It has proved a cost-competitive process for big Description Fast-reacting Pu components are filled with short fibers, mixed at high pressure and the where it cures quickly. series� using fast-reacting Pu systems, cycle times can mix is injected into the closed mold be as short as 90 seconds� Adding short fibers to the resin AX seriesIM-LGF R-RIM ON WEAR-RESISTANT MACHINES improves the stiffness, thermal stability and the thermal Features 1� Highly automated process The filler is mixed into one of the Pu components, in gene- expansion coefficient of the finished parts, making them 2� Short reaction and cycle times < 90 seconds ral the polyol, in a special premixing station� A piston mete- ideal for car bodywork elements� Stable, reliable production 3� Freeflowing materials can be processed into thin walled parts < 2 mm ring machine is used� In the mixing head, the filled polyol is systems and minimal post-mold processing meet the Pluspoints 1� Dimensional stability and inherent stiffness even at high temperatures EX seriesIMC mixed – intensively and at high speed – with the isocyanate requirements of the automotive industry� 2� Good paintability, even at temperatures up to 180 °C, inline painting during the shot and the Pu mix is injected into the closed 3� Low investment in molds and tooling mold� CX modular platform R-RIM is the only process for manufacturing Pu composite Typical applications Mudguards, door paneling, bodywork elementsFiberForm products where the reinforcing material is actually mixed Typical annual volumes 10,000 to 100,000 items into one of the Pu components� To reduce the abrasion risk, the mixing head and the metering system for the filledPolyset BMC/SMC component are treated for wear resistance� MX series LRX/IR seriesR-RIM RimStar seriesFCS Fillers Polyol Isocyanate PRODUCTS FROM KRAUSSMAFFEI MACHINES Comet seriesLFI PU mixing headsSCSHP-RTM PU dryside Part Car mudguard Part Door sill Mixing head Material Pu system with 22 percent wollastonite Material PuR-System with 22 percent wollastonite and 1 percent hollow glass spheres Technology R-RIM process on a multi-station system PU tooling Technology R-RIM process, automated part removalCellForm Benefits – High dimensional stability, tight length tolerances and post processing – Greater design freedom than for metals – Adequate flexibility and resilience Benefits – High dimensional stability – Low weight, wall thickness < 2 mm – Paintable inline Pu trimming – Excellent impact resistanceIMP 1� Inject into the mold 2� Reaction in the mold 3� Demolding
    • 16 FIBER COMPOSITE SOLuTIONS PROCESSES FCS – FIBER COMPOSITE SPRAYING 17 FCS – FIBER COMPOSITE SPRAYING LOW-COST MOLD, AUTOMATED SPRAYING USING ROBOTS, MULTIPLE VARIANTS – IDEAL FOR SMALL SERIES FIBER COMPOSITE SPRAYING IS A VERY FLEXIBLE PRO- come from a roving and be cut to length during the process, PROCESSES FCS – FIBER COMPOSITE SPRAYINGIM-SGF ZE uTX CESS FOR SMALL SERIES or ready-cut glass can be used� In most applications, fiber By pouring a combination of different Pu layers, it’s possi- length is between 5 and 20 mm and the fiber content in the Description Spraying a layer of fibers and Pu system in an open mold, air curing ble to produce composite parts exactly matched to specific part can be up to 25 percent� applications� Each different layer can be made completely AX seriesIM-LGF or partially of compact or foamed material, with or without STIFF SANDWICH PARTS FOR A MINIMAL INVESTMENT Features 1� Variable, application-specific layer structure (filled, unfilled and foamed layers) fiber reinforcement� Any specified wall thickness can be The FCS process is ideal for high-strength, very rigid, 2� Spraying into the negative mold – simple, lower-cost molds created and only one mold half is necessary� Because of the large-format, visible parts required in small quantities� The 3� Fiber content up to about 25 percent, fiber lengths between 5 and 20 mm lower initial investment, FCS is especially suitable for small process uses only a simple negative mold without a mold Pluspoints 1� Cost-competitive for small series, even for very large parts EX seriesIMC series� carrier� Although this is an automated, highly repeatable 2� Excellent surface finish through simple process combinations process, the tooling and investment costs are minimal� (eg, with In Mold Painting (IMP)) MODULAR SYSTEM CONCEPT The surfaces of the medium-sized or large parts can be 3� High stiffness and strength thanks to multiple layers CX modular platform In the simplest case, its possible to use just a 2C spray finished with a thermoformed film or using IMP (In MoldFiberForm mixing head with the appropriate metering machine� An Painting)� Typical applications Fenders, engine covers, large-format hoods and covers for machines optional H2O metering unit makes it possible to further vary Typical annual volumes 5,000 to 10,000 items the Pu system between compact or foamed� A 4-compo-Polyset BMC/SMC nent mixing head allows even more variability� Fibers are MX series metered coaxially into the Pu spray jet, ensuring that fibers are always optimally wetted with Pu� The glass fibers can LRX/IR seriesR-RIM RimStar seriesFCS Mixing head Fibers PRODUCTS FROM KRAUSSMAFFEI MACHINES Comet seriesLFI PU mixing heads PolyolSCS IsocyanateHP-RTM Pu dryside Part Hood for construction machine Part Car rear tray Material Pu long fiber reinforcement Material PuR with long fiber reinforcement and locally high fiber content Technology FCS Fiber Composite Spraying; visible surface Pu tooling Spray head can move in 3 dimensions produced previously in the same mold with In Mold Technology FCS, partly in multiple layersCellForm Painting (IMP) Benefits – Stiff, weight-optimized part, sandwich structure Benefits – Extremely cost-competitive process with honeycomb core – Automated production for small series – Strength (fiber content) locally varied – Premium surface quality – Low initial investment PU trimmingIMP
    • 18 FIBER COMPOSITE SOLuTIONS PROCESSES LFI – LONG FIBER INJECTION MOLDING WITH REACTIVE Pu 19 LFI – LONG FIBER INJECTION MOLDING WITH REACTIVE PU LIGHTWEIGHT MOLDINGS WITH HIGH IMPACT RESISTANCE – NOT JUST FOR AUTOMOTIVE In the LFI (Long Fiber Injection) process, endless fiber STABLE AND VERY LIGHT PROCESSES LFI – LONG FIBER INJECTION MOLDING WITH REACTIVE PUIM-SGF ZE uTX from a roving is chopped to length in a cutter. A blower Long fibers, wide freedom to design part geometries, and separates the filaments. Immediately after the cutter, the versatility of Pu systems mean that the application Description Glassfiber rovings are chopped close to the mixing head and wetted with the Pu system as the filaments are wetted with the PU mix from the mixing spectrum is very wide� LFI parts can vary from a small trim it is poured into the open mold� The mold is closed while the Pu cures� head. The fiber/PU compound is poured into the open part for a car interior to a large structural part with a Class AX seriesIM-LGF mold, under robot control, as a sharply focused spray A visible surface� Features 1� Fiber content and length can be locally varied cone. Once mold filling is complete, the mold is closed and 2� Easy integration of inserts (eg, clips and other connecting elements) the compound cures. Because this is a Pu process where mold cavity pressures are 3� Attractively priced raw materials, minimal fiber mixing < 10 bar, LFI also lends itself to producing high-strength sand- Pluspoints 1� First-class surfaces with simple process combinations (IMP, film inserts) EX seriesIMC SPECIFIC LOCALISED PROPERTIES wich elements where a honeycomb core is coated on both 2� High strength (fiber content up to 50 percent, fiber length 12�5–100 mm) Fiber lengths can be varied between 12�5 and 100 mm and sides with a Pu/LFI compound� Typical products here are rear 3� Moderate mold and machine costs fiber content can be varied continuously during pouring trays for cars or very large partitions� CX modular platform from 0 to 50 percent� 50 percent is the limit to ensure good Typical applications Engine hoods, roof elements, side trim, covers, flaps,FiberForm wetting with Pu� Today the most commonly used Pu sys- instrument panel substrates tems are either compact or foamed� This means that the Typical annual volumes 10,000 to 120,000 items property profile of LFI is comparable with that of SMC�Polyset BMC/SMC MX series LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES Comet seriesLFI 1. PU mixing headsSCS 4.HP-RTM PU dryside 1� In mold painting or film Part Radiator grill MAN truck Part Tractor bodywork element 2� LFI pour 3� Curing Material Pu with 25 percent long fiber reinforcement Material Pu with long fiber reinforcement 4� Demolding Technology LFI with thermoformed decor film; fiber length and Technology LFI, In Mold Painting for visible side PU tooling content can be locally varied to match part designCellForm Benefits – Large-format structural parts 2. Benefits – Mechanical strength can be locally varied to – Suitable for impact resistance suit part specifications – Ribbed structure to increase strength – Cost-competitive process for volume production – Painted visible part (IMP) – Class A surfaces PU trimming Movement in three dimensionsIMP 3.
    • 20 FIBER COMPOSITE SOLuTIONS PROCESSES SCS – STRuCTuRAL COMPONENT SPRAYING WITH REACTIVE Pu 21 SCS – STRUCTURAL COMPONENT SPRAYING WITH REACTIVE PU LOW WEIGHT; EXTREMELY RIGID COMPONENTS In SCS processes, layers made up of fiber mats and honey- CORE PLUS OUTER LAYERS PRODUCE EXTREMELY PROCESSES SCS – STRUCTURAL COMPONENT SPRAYING WITH REACTIVE PUIM-SGF ZE uTX comb cores are sprayed with unreinforced PU, inserted LIGHT, STIFF PARTS into a mold and pressed into shape. With substrate and core layers matched as regards material Description Spraying a pre-assembled sandwich with a Pu mix, transfer to a mold, pressing and curing properties and part geometry, it’s possible to produce extremely in a closed mold� THIN LAYERS ON LIGHTWEIGHT HONEYCOMB CORES light parts which are also very rigid� AX seriesIM-LGF This further development of LFI/honeycomb technology Features 1� Glassfiber mat in a holding frame sprayed on both sides with Pu reduces the thickness and weight of the cover layers to The SCS process has huge potential to produce lightweight 2� Combines easily with in-mold surface decoration make components which are even lighter� parts and this potential is far from being exhausted� Fiber 3� Lightweight component with honeycomb core First the sandwich structure is assembled – the honeycomb mats with endless fiber content and thicker Pu layers sharply Pluspoints 1� Optimized lightweight, moderate-strength parts EX seriesIMC core with fiber mats on either side� The sandwich is then increase the mechanical strength of the load-bearing edge 2� Low operating costs, low material consumption sprayed with Pu on both sides� Next the frame holding the areas� 3� High quality surface finish on both sides sprayed sandwich is inserted into the mold, which is then CX modular platform shut� During pressing, the fiber mats are impregnated with DECORATED SURFACE ON BOTH SIDES Typical applications Rear trays, cargo-area floors, large laminated parts, sun roofsFiberForm Pu� As the Pu cures, the fibers adhere to the fiber core� In the applications presented here, the surface decor Typical annual volumes 10,000 to 300,000 items inserts are positioned in both mold halves before pressing� The SCS process produces parts with ready-to-use surfaces�Polyset BMC/SMC MX series LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES Comet series 1.LFI PU mixing headsSCS 4. 2. 1� Assemble the sandwich 2� Spray a Pu layer on both sidesHP-RTM PU dryside 3� Press component into shape while Pu cures 4� Finished part ready for next process Part Sliding roof BMW X3 Part Rear tray Audi A3 Material Substrate: glassmat with Pu – paper honeycomb Material Substrate: glassmat with PU – paper honeycomb core – glassmat with Pu; core – glassmat with PU; surface: both sides non- Surface: both sides non-woven with barrier film woven with barrier film PU toolingCellForm Technology Structural Component Spraying (SCS) Technology Structural Component Spraying (SCS) Benefits Cost-competitive one-stage process Benefits Weight-optimized, rigid component Movement in three dimensions PU trimmingIMP 3.
    • 22 FIBER COMPOSITE SOLuTIONS PROCESSES HP-RTM 23 HP-RTM – HIGH-PRESSURE RESIN TRANSFER MOLDING VERY LIGHT, HIGH-STRENGTH VISIBLE AND STRUCTURAL PARTS In HP-RTM (High-Pressure Resin Transfer Molding), the HIGH PRESSURE AT HEAT PROCESSES HP-RTM – HIGH-PRESSURE RESIN TRANSFER MOLDINGIM-SGF ZE uTX first step is building up a high-quality fiber intermediate. Polyurethane, epoxy resins and polyamides are generally This consists of layers of carbon or glass fibers; the fabric used for the matrix� KraussMaffei offers the right machine Description The fiber mat or fabric is preformed and then positioned in the mold� The mold closes, the layers can be stitched or fixed together with a binder. The for each of these materials� While the maximum processing resin is injected and cures in the closed mold� exact structure of the intermediate will vary depending temperature for Pu systems is 80 °C, the epoxy resins and AX seriesIM-LGF on the load on the subsequent structural part and it may the casting polyamides used in HP-RTM require machines Features 1� Virtually unidirectional reinforcement with endless fiber or may not be preformed. The preform is placed in the modified to process materials at temperatures up to 120 °C� 2� High-pressure technology allows the use of fast-curing systems mold, the mold is closed and evacuated. Then a very low- 3� High fiber content – up to around 70 percent viscosity, reactive resin is injected into the cavity at high SHORT CYCLES AND FAST REACTION TIMES Pluspoints 1� Lightweight parts to meet highest specifications, around 50 percent lighter than metal EX seriesIMC pressure ensuring that each individual fiber is wetted and Whatever the material being processed, KraussMaffei 2� Visible part with high-quality carbon optics that there are no air gaps. machines are ideally suited for processing fast-reacting 3� Process can be fully automated for volume production (from preform production to post- systems; the mixing heads are all engineered for high- processing) CX modular platform OUTSTANDING STRENGTH pressure processing� The outcome is excellent mixingFiberForm The HP-RTM process produces extremely light structu- performance and fast reaction times� The mixing head is Typical applications Structural parts, side walls, floor pans, bumper carriers, crash boxes ral parts that meet the highest specifications, complying self-cleaning, so there are no stoppages for cleaning� We Carbon designer parts for instance with car crash test standards� Small-series also offer an extra module to meter in an internal release Typical annual volumes 10,000 to 120,000 itemsPolyset BMC/SMC applications in the aerospace, engineering and automotive agent directly at the mixing head� In this way, it’s possible to MX series industries are well-established, volume applications will configure a fully-automated, cost-competitive process� follow shortly� The HP-RTM process can produce parts with fiber content up to 70 percent� LRX/IR seriesR-RIM RimStar seriesFCS PRODUCTS FROM KRAUSSMAFFEI MACHINES 1. 2. 3. Comet seriesLFI PU mixing headsSCS 1� Intermediate cut from a roll 2� Handling the intermediate 4. 3� Transfer to the preform station 4� PreformingHP-RTM PU dryside 5� Transfer preform to HP-RTM station 6� Vacuum extraction (optional) Part Roof (visible carbon) BMW M3 Coupé Part Bumper carrier BMW M3 Coupé 7� Resin injection/curing 8� Part removal Material Carbon fiber fabric with EP resin as matrix Material Woven carbon fiber fabric with EP resin matrix 8. Technology HP-RTM Technology HP-RTM with ‘lost core’ for hollow part PU toolingCellForm Benefits – Visible structural part Benefits – Withstands very high structural loads – High-quality carbon sporty look – Very low weight, approx� 50 percent lighter – Pioneering application for other lightweight parts than a metal structure PU trimmingIMP 7. 6. 5.
    • 24 FIBER COMPOSITE SOLuTIONS SuRFACE ENHANCEMENT CELLFORM/IMP 25 CELLFORM (MUCELLTM ) IMP – IN MOLD PAINTING GENERATE FOAM STRUCTURES IN LIGHTWEIGHT HIGH-QUALITY PAINTED SURFACES INJECTION MOLDING – OR ADD EXTRA LIGHTWEIGHT STRAIGHT FROM THE MOLD – FULLY POTENTIAL TO INJECTION MOLDING INTEGRATED PAINTING PROCESS MUCELLTM: BLOWING AGENT REDUCES WEIGHT AND COLORS GALORE IN A STRAIGHTFORWARD PROCESS:IM-SGF IMPROVES PRECISION MOLDING IN MOLD PAINTING MuCellTM is a physical foaming process for thermoplastics� In IMP, the paint and/or primer system (barrier coat) is It uses nitrogen or carbon dioxide as blowing agents� The sprayed either manually, or by a robot, into the open mold� gas is transformed into a super critical fluid (SCF), fed into The spray system can consist of one or two components�IM-LGF the plastic melt towards the front of the barrel and mixed The IMP technique allows for flexible color management with it� The SCF expands during the injection process to and fully meets most product specifications� The substrate produce a part with a mainly microcellular foam structure material is either injected or sprayed, eg, using LFI or (< 100 µm)� The MuCellTM process offers clear benefits, even FCS technology, into the mold after the paint layer� TheIMC with low volumes of blowing agent� combined system then reacts in the closed mold to give a – Weight savings through lower densities resilient, uniform surface finish� – Higher dimensional stability and fewer sink marks as the blowing agent expandsFiberForm – Shorter cycle times thanks to higher injection speeds and eliminating holding pressure� – Lower clamping forces due to lower material viscosityPolyset BMC/SMCR-RIMFCS Back check valve SCF interface kitLFI SCF injectorSCS Front check valve 100 µm paint layer 200 µm primerHP-RTM Substrate SCF homogenized with the melt N2CellForm SCF injectionIMP Plasticizing the resin SCF metering system
    • 26 FIBER COMPOSITE SOLuTIONS SYSTEM AND PROCESS EXPERTISE/TECHCENTER 27 CONSULTING – TESTING – IMPLEMENTATION TECHCENTER FOR INJECTION MOLDING AND REACTION TECHNOLOGY SYSTEM AND PROCESSING EXPERTISE FROM IDEA TECHCENTER FOR LIGHTWEIGHT DESIGN TO PRODUCTION AND FIBER COMPOSITE TECHNOLOGIES Partnerships are often launched during purely informative SOLUTIONS FOR SERIES PRODUCTION New ideas for components often also require new or ad- OPEN AND YET DISCREET discussions on all sorts of occasions. Once the component and the production process have been apted production processes. For an idea to be successful, Mutual trust is a must when it comes to new processes and agreed, we’ll work with you to develop the best production the associated production process has to prove itself in developments� To ensure the necessary confidentiality and THE FIRST IDEA solution� The degree of automation, postprocessing and practice. to protect our customers’ know-how we reserve separate The very first sketches and ideas define some of the para- coordination of downstream operations are all important production areas for each customer during trials and tests� meters for the production process� Even at this early stage, considerations� We will then quote for a solution optimized MACHINE AND PROCESS EXPERTISE our specialists are on hand for advice and consultation with respect to capital investment and unit manufacturing The KraussMaffei TechCenter with its unique combination to help our partners to work out appropriate and flexible costs� of injection molding and reaction machines makes it easy solutions� Feasibility studies consider possible production to test and optimize or advance your processes using processes and downstream operations� PROJECT AND IMPLEMENTATION PHASE experimental carriers or first prototypes� At your service Our experienced project engineers are on hand to give you in the TechCenter is a team of process developers, appli- PROCESS DELIVERS SPECIFIC COMPONENT PROPERTIES support – from planning and implementation to on-site pro- cation engineers and technicians� The close cooperation As a component takes on shape and size, reliable material duction start-up and even complete project� at KraussMaffei between experts in the fields of injection data are essential in order to design for different load cases� molding and reaction technology generates new and different Especially for fiber composite structures with anisotropic PRODUCTION SUPPORT approaches and results in synergies and new ideas from characteristics, process trials are important for validating We spare no effort to ensure a problem-free production which you will profit� the production process and component properties� start-up – from providing process and machine know-how to training your machine operators and maintenance tech- WATCH THIS SPACE PROTOTYPING AND FINE-TUNING nicians� Our TechCenter for injection molding and reaction techno- In our TechCenter we have facilities for producing prototypes logy covers an area of 4000 square meters and is populated and preproduction parts� This learning phase also shows up SERVICE with over 25 machines and systems for various production further optimization opportunities for the production process� After the production start we continue as your reliable partner� processes� Specifications Component concept, Component and Prototyping, Maintenance, service, Idea preliminary Feasibility study Detailed design Series preparation Production planning Production support Training, practice process validation trials upgrading development Customer satisfaction
    • 28 FIBER COMPOSITE SOLuTIONS Pu MOLD TECHNOLOGY / DEVELOPMENT SuPPORT 29 PU TOOLING TECHNOLOGY DEVELOPMENT SUPPORT LET YOUR VISIONS OF STRUCTURAL ON-THE-SPOT TESTING FOR COMPONENTS TAKE SHAPE WITH PROTOTYPE PARTS SPEEDS KRAUSSMAFFEI PU MOLDS AND PRESSES PRODUCT DEVELOPMENT With our combination of best-practice processes and mold PU MOLD TECHNOLOGY – FINE-TUNED FOR Component testing is a major milestone on the way to a EXTRACT FROM THE KRAUSSMAFFEI TESTING PORTFOLIO technologies, we can help you turn your idea for a struc- EACH SPECIFIC APPLICATION volume-production component. KraussMaffei operates in- Vibration & shock: electrodynamic vibration testing tural component into reality. Working with polyurethane KraussMaffei molds can be adapted to a large number house component testing services; one immediate use for equipment enables us to simulate all mechanical loads as and intermediates, KraussMaffei can supply the complete of different processes� This opens up new options for the results is to optimize manufacturing cells and PU molds. defined by national and international standards or to OEM manufacturing system, including the process know-how producing structural components� Each mold is specially The facility contributes to faster time-to-market for your specifications� If required, temperature and climate profiles and the mold – from our own resources. Single-vendor engineered for a specific application and fine-tuned to products. A system partnership with KraussMaffei shortens can be imposed on the vibration� solutions guarantee that all the elements of your system production requirements: your communication paths and ensures significant time Climate, sunshine, heat and cold: our test lab is equipped will work perfectly together. The bonus of dealing with – Temperature control matched to process requirements savings on the way from design study to volume production. to simulate extreme weather and temperature conditions just one partner for the whole system is streamlined, fast – Extra wear protection where necessary, for instance, if with precise repeatability and assess their impact on test project completion saving you time and hassle. you’re processing abrasive materials ISO-ACCREDITED TESTCENTER samples� – Optimal ejector concept for damage-free part demolding Our test lab is accredited to DIN EN ISO/IEC 17025 : 2005 Temperature shock: The temperature shock test provokes TOOLING TECHNOLOGY FOR FORMING AND SHAPING – Seal technology to suit the product and is specifically equipped to test components and assem- the mechanical stresses which can occur when compo- Fiber composites are often processed in the form of inter- – Optionally with integrated trimming solution blies for automotive interiors and exteriors� nents made of materials with different thermal expansion mediates� KraussMaffei’s modular mold concepts can be behavior are exposed to extreme temperatures, which can configured to mold any specific type of intermediate� This We have the facilities and the in-house expertise to test ultimately destroy the component� mold technology enables us to offer turnkey system solu- safety-critical chassis and structural components, elec- Corrosion: the corrosive properties of salt spray atmos- tions to manufacture a huge range of products – as prototy- tronic control devices and pyrotechnical safety restraint pheres and condensate can damage materials and sur- pes and for series applications: systems� On request and after intensive consultation, we’ll faces� Especially in the automotive segment, corrosion – For glassfiber-reinforced structural components also develop customized testing programs� resistance is a significant sign of quality and safety� – For parts made of natural fiber composites – For LFI processes – For a wide spectrum of foaming and casting processes Heated press mold for fiber composite parts Mold for the LFI process
    • 30 FIBER COMPOSITE SOLuTIONS SERvICE SERVICE WORLDWIDE SERVICE, SUPPORT AND SPARE PARTS – OUR SERVICE TEAMS: WHEN YOU NEED THEM, WHERE YOU NEED THEM ON CALL FOR YOU WORLDWIDE Rely on us for a fast and competent response to all your CUSTOMER TRIALS AND PROTOTYPING IN OUR TEST LAB service needs anywhere in the world. Whatever you need – The Injection Molding Division operates a test lab fitted with from troubleshooting and training to spares or repairs – we’re the latest machinery and equipment� We can run trials, pro- on the job. We’re dedicated to supplying service quality duce prototype parts and fine-tune processes on your behalf� on a par with the outstanding quality of our machines and We can work with you to test and evaluate processes, ma- systems. We offer far more than spare parts and hotlines. chines and equipment in order to identify the best approach Russia (Moscow) We’ll work with you to choose the best and most cost-ef- for a particular project� Our highly-qualified application UK (Warrington) fective solution for your operation. We’ll help you test new engineers are there to help you� America Europe applications and we’ll plan customized service packages. USA (Florence and Detroit) Germany (Munich) Korea (Seoul) TRAINING WITH HIGH HANDS-ON CONTENT Spain (Barcelona) Asia/Near East ALL-ROUND SERVICE Courses are held in our lab and training center, or, optio- Italy (Abbiategrasso) Japan (Okazaki) Our service offering is broad� We’ll configure your system, nally, on your premises� We offer clearly-structured basic install and commission it, train your staff, plan measures to and advanced training in operation, process control and China (Shanghai) minimize your downtime risk and maximize productivity, and maintenance for KraussMaffei machinery� On request, we’ll Mexico (Mexico City) carry out maintenance, repairs and upgrades� You’ll find us plan and hold special courses on topics of your choice� fast, reliable and competent� Our hotline is manned by high- All participants spend a high proportion of their training ly- trained and experienced service technicians� If necessary, working hands-on with original KraussMaffei machines� A Singapore (Singapore) we’ll get a technician to you quickly� Remote diagnosis, inter- well-structured training program produces skilled operators facing directly with your machine’s control system, can be a and technicians, which will positively impact your up-time practical alternative� Spares for all important wear parts are and productivity� available at short notice� We’re continuously expanding our Brazil (São Paulo) service network to speed up spare parts shipment� Talk to us Injection Molding Machinery about the right service solution for your business� Reaction Process Machinery CONTACT In addition to our regional service centers, you can also contact our after-sales and spare parts service worldwide via this address and hotline: KraussMaffei Technologies GmbH Krauss-Maffei-Strasse 2 80997 Munich Germany Service hotline Phone: +49 (0)89 88 99 0 www.kraussmaffei.com
    • In many sectors, component specifications are beingratcheted continuously upward. Typically, customerswant higher mechanical strength and lighter weight. 2.0 WE . 1st edition 06/11 ··· KM 00001 BR 06/2011 EN ··· KraussMaffei reserves the right to make technical changes ··· Printed in Federal Republic of Germany.KraussMaffei is a globally active engineering company.With our machinery and processes, together with ourwide experience and a clear understanding of yourvalue-adding chain, we offer highly automated systemsfor the production of lightweight, fiber-composite parts.Our machine portfolio and know-how puts us in aunique position to deliver the very best matchbetween manufacturing technology and your partspecifications and target volumes.You’ll find KraussMaffei the ideal partner as you workto transform your visions into reality.KraussMaffei Technologies GmbHKrauss-Maffei-Strasse 280997 MunichGermanyPhone: +49 (0)89 88 99 0Fax: +49 (0)89 88 99 22 06www.kraussmaffei.com