At JEC World in Paris, France, from March 12 to 14, 2019, KraussMaffei will be at booth 6-R28 to highlight its leading systems expertise in developing and implementing mass-product-ready processes for fiber reinforced lightweight structures, With a focus on new processes and applications based on both thermosetting and thermoplastic base materials, including FiberForm processes, pultrusion and unidirectional (UD) tape technology.

Injection molding, reaction processing and extrusion are the three major technologies of the Kraussmaffei Group, making the company the only one-stop supplier in the world to cover all three technologies at the same time.

" We offer process-independent advice to our customers, accompanying them from concept to mass-production-ready fibre-reinforced composite solutions. This expertise, together with our experience and references from mass producers around the world, sets us apart. In this way, we are able to offer solutions along the entire process chain and work closely with industry and research partners." Nicolas Beyl, General Manager of the Reaction Molding Technology Division of Kraussmaffei Group.

parts with partially enhanced function and appearance are produced in a single injection process each year: The combination of multi-component technology and the FiberForm process opens up endless possibilities for functional lightweight structures in exterior automotive parts.

How do you translate system ideas into a mass-production-ready process? Kraussmaffei has the answer with technologies such as the FiberForm process.

Intelligent automation solutions and heating technology are optimized for injection molding processes, ensuring cycle times of less than 60s.

For the first time, a mass-produced continuous fiber-reinforced thermoplastic lightweight component with more than 1 million pieces per year will be on display at JEC. The component is produced by shaping and back injection of a stable fiber-reinforced composite material called "organic sheet".

This organic sheet is only 0.5 mm thick, but ensures the required stiffness with a low dead weight and makes an important contribution to vehicle weight reduction, up to 4 kg per vehicle.

This injection molding process contributes to the stability of the geometry and adds functionality to the parts.

Another sample part, from a research project in collaboration with the Technical University of Dresden, will demonstrate the use of recycled materials such as recycled carbon fiber and re-produced blends.

In another breakthrough innovation, the injection molding production technique known as "foam molding" is implemented on a complex shape. This technology makes it possible to produce thermoplastic sandwich structures in a single injection process using a fiber-reinforced overlay.

The third application is the central armrest for Automotive interiors, which successfully combines the FiberForm process and rotary formwork technology for multi-component injection molding and will be showcased in the Planet Area Automotive section of the JEC show.

" This combination can be used to create entirely new visual and tactile component features for thermoplastic composites in a single process step. The TPE group's division into the functional and visible parts of the central handrail brings an exceptionally soft and attractive surface." Says Dr. Mesut Cetin, Group Product Manager at Kraussmaffei Automation.

The application of composite sheets increases the rigidity and strength of the parts, which allows the stiffeners and the parts themselves to be designed thinner, resulting in a weight reduction of about 20% and a cost reduction of about 15%.

The system solution took the market by storm: Kraussmaffei's iPul system is ideal for pultrusion profiles and rods used in the construction and wind energy industries

Another highlight of Kraussmaffei's stand was the iPul technology from Kraussmaffei's Reaction Forming Technology division. With the launch of this system solution in 2017, the company has set a new standard for pultrusion.

As a continuous production process for fiber-reinforced profiles and round rods, the iPul system boasts a faster production speed compared to the usual open bath process.

" Our iPul system is exactly what The Times call for. This new technology is getting a lot of interest from the construction (like window profiles or concrete rebar) or wind energy industries. In this area, we have recently received a series of orders for a large project in Russia." Philipp Zimmermann, head of Kraussmaffei's Composites/Surface Technologies business unit.

Like the energy and power sector, the automotive sector also offers great potential.

" In the automotive sector, together with Tier 1 suppliers and Fraunhofer IGCV, we have launched two forward-looking development projects, thereby demonstrating here the true capabilities of pultrude: From the investment point of view of systems and tooling, fiber-reinforced composite profiles enable low-cost production with low barriers to entry, which makes lightweight structures even more attractive." Zimmermann said.

The new iPul system takes KraussMaffei boldly for the first time into the field of complete turnkey systems where "the system, process and die technology are all sourced from a single supplier" and where important process parameters, such as output and traction speed, can be centrally controlled.

Another advantage of the iPul is the great flexibility and precision of the system. The injection box and the metrology technology using the newly developed mixing head make it possible to process completely different resins, even polyurethane systems.

Primary surface for large parts

Long fiber injection process (referred to as "LFI") produced by LFI process is a series of system solutions developed by KraussMaffei for fiber reinforced lightweight structures.

" This long fiber injection process is ideal for large size, complex and thin-walled components. Typical end applications include appearance parts for trucks, commercial vehicles and agricultural machinery, especially in China and the United States, where we see great potential." "Zimmermann said.

A high degree of automation ensures a shorter production beat; And a high fiber volume content of up to 50%, ensuring a light component weight while also having a high degree of stability.

LFI parts feature high temperature stability and excellent impact strength, with a surface quality that can be used immediately after stripping. At JEC, Kraussmaffei will be presenting a range of components for tractor side covers.

As a specialist in extrusion technology, Kraussmaffei - Belstorf has adopted UD belt to further enhance the competitiveness of its FiberForm process.

UD tape features a unidirectional reinforced fiber material, such as glass fiber or carbon fiber, embedded in a thermoplastic matrix.

" For the FiberForm process, UD bands provide an ideal foundation for organic sheets. We are eager to demonstrate our rock-solid system expertise to our customers at JEC. We are leveraging our expertise in extrusion and thermoplastic lightweight structures and tying it with injection molding technology to develop new and ingenious lightweight structural solutions." "Says Hilmar Heithorst, product Manager at Kraussmaffi-Berstorf.

Another important application of UD belts is thermoplastic composite pipes ("TCP" for short).

A TCP system wraps the UD tape around the plastic pipe and then melts the layers. This composite material, along with the orientation of this longitudinal fiber, provides them with incredible compression resistance, making them ideal for applications in the oil and gas industry.

In developing the UD belt technology, Kraussmaffei worked with the Fraunhofer Pilot Plant Center for Polymer Synthesis and Processing ("PAZ") in Schkopau, Germany, which since 2017 has been home to the new UD belt system, the world's largest melt impregnation facility. The UD belt system achieves production speeds of 20m/min at processing temperatures of up to 350 бу C.

Plastic Industry Video