With ColorForm, multiple-component parts - including those made from fibre-reinforced plastics - can be coated in a single process to give them a high-quality surface - as seen in this tool case.

The latest development here is a process called ColorForm which the machinery producer KraussMaffei, the tool engineering specialist Hofmann and the surface systems producer Panadur, have developed. The combination of ColorForm and LFI (long fibre injection) technology allows large components to be made with glass fibre reinforcement; the shiny surfaces are created directly in a single process in a closed mould.

In conventional coating methods, the products have to be cleaned and in some cases primed or masked separately. The newly developed technique permits coating processes which offer superior time, energy and cost-efficiency. The solution is an interdisciplinary fusion of technologies which includes injection moulding and reaction engineering. It permits single-stage manufacture of multiple component parts with extra functions, optimised haptic properties and a high-quality surface.

The solvent-free, highly reactive material is injected into the mould using a high pressure injection method. The carrier material, e.g. polyurethane, epoxy or polyester resin, is then introduced to the open or closed mould to create an adhesive bond with the coating material. Composites are ideal here for reducing weight. At the end of the reaction time the moulded part is removed from the mould. The result is a part with a shiny, matt or textured finish, depending on the mould.

KraussMaffei and Panadur are just two of the project partners appearing at the exhibition for fibre composite solutions, the Composites Europe (CE). The international trade fair is to be held from 27 to 29 September 2011 in Stuttgart. Lightweight materials for consumer goods figure prominently and numerous companies will be presenting their latest developments in this field.

The RELAY (Rapid, Efficient, Layup) Station creates tailored multi-ply preforms from unidirectional thermoplastic prepreg tape that can then be formed into a final part. Unidirectional tape combines a reinforcing fiber, such as glass and carbon fiber, with any of a variety of thermoplastic resin types, such as Polypropylene, Polyamide, or PEEK. Tailored blanks™ can be made with locally varying thickness and fiber orientation to maximize structural performance. The fully automated RELAY Station reduces the labor intensity of advanced composite part manufacturing, thus expanding the commercial reach of these materials into higher volume markets and products. Tailored blanks can also be used as structural inserts in injection and compression molded parts for cost and shape-stiffness optimized solutions.

“With its long history of innovation in thermoplastic composite processing, complementary partnerships with other firms, extensive capital equipment, and staff of industry-leading composite experts, Fraunhofer ICT was a natural choice for establishing a development and demonstration centre in Europe,” says David Cramer, Fiberforge’s Chief Technology Officer. “Through this new partnership with Fraunhofer ICT, we will be able to work more easily with customers to apply the technology in new products and in combination with other thermoplastic processing technologies.”

Prof. Dr.-Ing. Frank Henning, Deputy Director of the Fraunhofer ICT explains the benefit on the European side: „Fiberforge’s innovative tape layup process opens up new possibilities for producing thermoplastic advanced composite parts in a fast and automated process. Combined with our expertise in other thermoplastic processing technologies, Fiberforge’s RELAY Station will expand our portfolio in the research and development of process technologies for fiber-reinforced plastics.”

Fraunhofer ICT Information
Fraunhofer ICT scientists carry out research and development work in the business areas of defense and security, air and space travel, automotive and transport technology, chemistry and process engineering, energy and environment. Fraunhofer ICT is one of the 59 institutes that currently make up the Fraunhofer Society. Beside contract research for industry, the Fraunhofer ICT also works closely with commercial companies, often through research projects co-financed by the German government or the European Union.

About Fiberforge
Fiberforge is a technology company that is commercializing breakthrough manufacturing systems that enable the affordable production of lightweight advanced composite parts at high volumes. Fiberforge’s proprietary RELAY® Station—protected with multiple patents and trade secrets—produces parts with high fiber alignment, high fiber fraction, and long fiber length at high speed with minimal scrap. Fiberforge’s technology and its tailored blanks are protected by US patents (6,607,626, 6,939,423 and 7,235,149), US patents pending and International patents granted and pending.

Any projections and forward-looking statements in this release are based on best practice analysis and research from independent advisors to Fiberforge. The conclusions drawn, while the result of the best efforts of the staff of Fiberforge, are in no way a promise of delivery, and they can, and will, be changed according to future input.

The stick was used by the Swiss Team at the Hockey World Championship 2009 and was also praised by the Russian, Austrian, Latvian and French teams.  The new, patented nanotechnology provides the hockey stick with its specific strength and thus improves its impact characteristics as well as its reaction where bending, resistance and torsion are concerned.  In addition, the energy released by the player is passed directly and efficiently to the puck due to the one-piece design.