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www.formaplex.com WORLD-CLASS MANUFACTURING SOLUTIONS

WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

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Page 1: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

www.formaplex.com

WORLD-CLASS MANUFACTURING SOLUTIONS

Page 2: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Providing world-class manufacturing solutions for tooling and niche components using advanced materials

Page 3: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Formaplex is a dynamic product development company established in 2001

3

350+ EMPLOYEESworldwide

57

37

15

2001 2004 2007 2011 2013 2015

37

45

15

8

15

Page 4: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Continually investing in state of the art facilities

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Page 5: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Our footprint is across market sectors and built on a can do approach to exceptional delivery

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Page 6: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Complete solutions for composites and thermoplastics

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Injection mould tooling Plastic components & assembly Component machining

Composite patterns & tooling Composite components Jigs & Fixtures

Page 7: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

WP#1; Benchmarking

WP#2; Material Handling & Preforming

WP#3; Tool Technology & Process Optimisation

WP#4; Analytical Studies

WP#5; Case Study Manufacture

Q3 2014 – Press HP-RTM cell specification

Q3 2015 – Press HP-RTM cell commissioning

Q2 2016 – Case Study Evaluation

4 trials complete

Flow front simulation

Cure distortion prediction

RITAA - Resin Injection Technologies for Automotive Applications

Page 8: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

RITAA project partners

Lead partner providing resin systems and facilities

Providing HP-RTM equipment to Cytec, processing expertise

and facilities

Providing multi axial fabrics

Providing tool design and manufacturing expertise

Providing moulding simulation tools to provide mould tool

geometry compensation data

Page 9: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

High Pressure Resin Transfer Moulding

Preformed dry carbon or glass fabric component loaded into matched metallic

heated tooling

Resin injected at pressure in 20-30s

100 bar internal cavity pressures achieved

3-5 minute cure duration at 120-130⁰C

What is HP-RTM?

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Resin Hardener

Preform component inserted and

pressed under vacuumMixed resin and hardener injected Cured part removed after 3-5 minutes

Page 10: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

What are the benefits to UK industry?

Continuing weight reduction

demands require advanced material

and production solutions

Traditional composite solutions are

slow and labour intensive

Auto industry requires 90 second

TAKT times or close

HP-RTM has been demonstrated to

be a high volume automotive solution

for automotive carbon fibre

component production

Page 11: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Formaplex has designed and manufactured a steel development tool

� 1.2mm, 2mm, 3.2mm & 4mm thick components

Formaplex HP-RTM tool

Page 12: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Successful trials at Krauss-Maffei and NCC

Page 13: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

LMAT tool surface compensation

Residual stresses that develop

during cure result in distorted

composite components

Using the LMAT tool the infusion and

cure process can be simulated to

predict the final distorted shape

The tool surface geometry is then

modified to compensate for cure

distortion

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Page 14: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Next steps

A representative case study

component has been selected – a

generic A pillar reinforcement

Demonstration at Cytec of the cost

effective manufacture of the case

study component, using HP-RTM,

within a 5 minute cycle time

Page 15: WORLD-CLASS MANUFACTURING SOLUTIONS - Easyfairs · Providing world-class manufacturing solutions for tooling and niche components using advanced materials. Formaplex is a dynamic

Thank you

FormaplexAccess PointNortharbour RoadCoshamHampshire PO6 3TEUK

Mobile +44 (0)7703 680072Direct Dial +44 (0)2392 590449Email [email protected]

MATT SELLENSBusiness Development Manager

www.formaplex.com

FormaplexAccess PointNortharbour RoadCoshamHampshire PO6 3TEUK

Mobile +44 (0)7900 606215Direct Dial +44 (0)2392 590441Email [email protected]

IAN WILSONComposites Director

www.formaplex.com