Composite Fabrication
Owing to the close cooperation of our specialized staff and engineers DG Composites is able to offer customer-focused solutions for the manufacturing of composite components. Construction method and materials are chosen individually, depending on the specific element and its requirements.
Synopsis of different Manufacturing Methods
Hand lay-up
Most of our projects are realized in hand lay-up laminate. Fibers are laid into the production medium and soaked with resin by hand. The manual worker uses paintbrush, roll and other appliances to treat the work piece. However this is the oldest fabrication method it offers some crucial advantages and therefore is still interesting for many projects.
Vacuum Method
The vacuum method is primarily used to fabricate so called sandwich structures. A kernel of aramid combs or rigid foam is placed between the layers. A vacuum which compresses all the different layers is put upon the production tool. The specific layers are thus pressed together until the resin is cured. The vacuum method may also be necessary with complex component shapes or when looking for a particular target weight. The costs for tools are relatively low compared to other techniques like RTM or Pre-Preg.
Resin Infusion
Components produced with this method are of a tremendously high quality and the process is reproducible. Dry fibers are laid into the production medium, covered with a plastic film and then vacuum pressed into the mold. The component is soaked with resin via the vacuum; the negative pressure controls the process of sucking resin into the laminate until the resin after propagating into the component has reached the connection of the vacuum. After the infusion procedure is completed the component hardens inside the perpetuating vacuum. This method is especially suitable for high-quality components or for the mass-production of specific elements. Often the work of designing such components is more elaborate, considering the manufacturing process and production tools.
RTM-Light
Resin Transfer Molding (RTM) is available in different versions and stages. At DG Composites we use the RTM-Light process. Similar to the vacuum method dry fiber is laid into the production medium, but no plastic foil is needed to apply a vacuum in the production mold. The work piece is sealed with a second half of the mold. Now both halves are compressed in a vacuum and the resin is like with the infusion technique lead into the component. This method is especially suitable for the mass-production of specific elements. Tool costs are relatively high. In the end both sides of the component are even and can easily be painted. Furthermore the component will have a defined wall thickness.
