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www.formaplex.com
WORLD-CLASS MANUFACTURING SOLUTIONS
Providing world-class manufacturing solutions for tooling and niche components using advanced materials
Formaplex is a dynamic product development company established in 2001
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350+ EMPLOYEESworldwide
57
37
15
2001 2004 2007 2011 2013 2015
37
45
15
8
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Continually investing in state of the art facilities
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Our footprint is across market sectors and built on a can do approach to exceptional delivery
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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
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
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
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
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
Formaplex has designed and manufactured a steel development tool
� 1.2mm, 2mm, 3.2mm & 4mm thick components
Formaplex HP-RTM tool
Successful trials at Krauss-Maffei and NCC
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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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
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