Dieffenbacher production procedures presented at JEC World enable shorter cycle times and more efficient production processes, making it possible to use large-series fibre reinforced components in the automotive and aerospace industries.
Tape-laying Process: Faster and more precise with the tailored blank line
With the tailored blank line using the Fiberforge and Fibercon systems, Dieffenbacher offers a solution for the large-series production of locally reinforced thermoplastic components.
In the first step, the Fiberforge produces near-net-shape composite lay-ups from unidirectional carbon fibre and/or glass fibre prepreg tapes. One laying cycle lasts about 1 second, making this system the fastest tape laying system in the world, Dieffenbacher says. After a laying pattern is defined, the tapes can be rolled off of coils and laid according to that pattern. The Fiberforge system can carry four of these coils. This makes it possible to mix different materials in one tape lay-up. Even the width and thickness of the tapes can be varied.
With a new angle-cutting system, the start and end of the tape can be cut variably either straight or at an angle of ±45°. Precise and near-net-shape tape laying reduces excess bleed cuttings. An automatic coil exchange system guarantees uninterrupted production.
In the second step, Fibercon uses vacuum-assisted forming to form the tape lay-ups into a near-net-shape laminate. The Fibercon can process several lay-ups simultaneously and has short cycle times. The vacuum-assisted forming system minimises air pockets and material faults and reduces the level of oxidation, producing unparalleled laminate quality.
Together with downstream systems such as handling robots and compression moulds, the Fiberforge and Fibercon systems make it possible to produce more than 1 million components per year.
New generation of CompressLite
The new generation of the CompressLite press series offers improvements in many respects. Thanks to high speeds and short pressure build-up times, CompessLite has been optimally adapted to thermoplastic processes. The newly developed control and visualisation of the CompressLite allows a comfortable and intuitive operation. The result is a modern product design that delivers the latest future-proof technology along with maximum profitability and efficiency.
Visit Dieffenbacher in Hall 6, Stand C31 at JEC World 2018.