BIG TURN OUT IN CANADA.
We've been delighted to share our technology with so many enthusiastic composite North American moulders. Coming mainly from Canada we also had visitors from USA and one from Japan at our 34 attendees Masterclass. Hosted by FormaShape in Kelowna, BC 4 different mould designs were converted to closed mould reusable vacuum membrane technology. Unlike some who just demonstrate a system, our Masterclass actually taught all the techniques and supplied a valuable 52 page illustrated technology manual. Visitors were, therefore, able to leave with a full working knowledge and to immediately put into operation what they had learnt back at their moulding facilities. After completion each mould was gel coated and glass loaded to clearly show the rapid fill and cure to completion of the ~VPI moulding process. All the very latest features including Morph resin runners, Reflow, and moulded 110% vacuum secure where clearly applied and production used for all to see the benefits of these unique innovations.
THE -ARC –ANGELS , SPECIALIST car body supplies .--NEWS
Tristan White , head of ww.w.the-arc-angles has shown great wisdom in taking on the VPI reusable vacuum membrane process. These original style Mini car wheel spats are cluster moulded almost akin to high pressure thermoplastic moulding but here with high quality and strong reinforced glass fibre.
Using a staggering 60% less resin than consumed by the former hand lay process Tristan’s team are able to mould in 5 minutes a set of four and achieving Zero clean up. The system gives them a professional, far better rear surface finish and consistent thickness. The VPI process allows fill to mould each with the 5 screw down fixing shaped rear bosses. Tristan, remarks they are happy customers for this improvement to efficient frp. production.
OVER 200C HOT
Yes, that is my hand on the edge of the heated reusable vacuum membrane. A few mm further in and it is at an incredible 203.8C.
Heats up to this in less than 100 seconds. This shows how resilient and safe our unique in "bag" heating is. Want to do some reinforced thermoplastic vacuum moulding then you need to use this system. The face metal mould is SS 1mm thick and also heated. Power input equivalent to 5kw/m2. This system is running on safe 35vac
LEADING AUSTRIAN MOULDER TAKE ADVANTAGE OF REUSABLES
KK Composites GmbH, Austria’s leading fibre composites moulding company have met greater demand by converting from traditional resin infusion techniques and choosing Reusable Vacuum Membrane Technology. Using our unique reusable flow media such as Morph Runners and Reflow (moulded into membrane flow grid), the need for costly one-time use infusion consumables is eliminated and set-up times are greatly reduced. We were very happy working with KKC earlier this month who were looking for an efficient system to help them deliver shorter processing times. KK Composites staff were all trained in the reusable manufacture technique and are keen to take advantage of this cost saving system.
PUNE – INDIA, SCHOOL AT OUR MASTERCLASS EVENT
On Friday, ECS, Pune conducted a new technology update course on the method and use of this exciting reusable vacuum membrane technology for composite moulders.
Even though over 4000 miles away we were linked to the course to provide a question and answer session on Skype covering many good questions like how much filler can be used? Can phenolic resin work under reusables, How big can the system mould. Further, it was possible to show via the video link a train seat moulding illustrating the feature of extremely low wastage almost net size and how these parts have been made over 2500 times without one reject by VPI. We thank ECS for teaching another 24 attendees from the Indian composites sectors.
RALLY Tech SEATS
Using Saertex quadriaxial up to 3.5 kg /m2 fibre loading Rally Tech UK developed reusable vacuum membranes to streamline their production. High fibre content is important and the quadriaxial with Saerfix allows accurate placement and hold in these complex seat shapes. RallyTech client, Motordrive ltd, witnessed the reusable being manufactured this week at our Plymouth facility. The Saertex materials are available in UK from Christex Ltd. This mould reusable membrane has double "H" morph resin runners built in . Morph as some of you know means no peel ply needed as after infusion the runner flattens against the fibre leaving no trace of resin line. Exceptionally smart !!!
SIFT CENTRE MALAYSIA BRINGS STRONG AWARENESS OF NEW TECHNOLOGY
Malaysia’s composite manufacturing community furthered its technology training with yet another excellent presentation by TK Lim , head of SIFT Center , Kuala Lumpur .Malaysia’s top academic college KKTM (Kolej Kemahiran Tinggi Mara) learnt the ease and flexibility of our fiRST moulding technologies. Trained in the modern methods of rapidly manufacturing three dimensional fitting reusable membranes the group witness for themselves how all types of fibre could easily be moulded under the same vacuum reusable.
Sift have now become our major training centre in the far east spanning from India through to Japan. Equipped with all the latest machines and ancillaries clients are brought up to date with reusable vacuum membrane technology through SIFTs training programs.
MORPH RESIN INFUSION RUNNERS INSTRUCTIONS. UPDATES
Since last year's introduction of the innovative Morphing infusion resin runners, the company has updated the instructions and published to all their users. This design now eliminates wasted resin and exothermic print through as they leave no resin runner hardened resin witness on the B side of the moulded part. In certain instances, they also remove the need and cost of peel ply and flow mesh in composite liquid moulding processes. Call us today for full copy of latest manual.
“Simplicity, the true key to good design”
MAGLOC is a new composite mould air ejector comprising of just two hardened precision steel parts locked together with neodymium magnetism. This provides the simplest solution to construction and assembly bringing attractive low cost. Further more in contact with the cured moulding allows its 10mm diameter smooth face safely ejects the part locally to allow controlled high pressure air follow through to fully eject the component.
After years of marketing more complex and pricey ejectors it was time to re-evaluate and innovate a simpler far less costly solution. The MAGLOC air ejector is the result bringing a robust, low cost alternative to market for the moulding community.
The mould builder can either mould MAGLOC into a composite mould or retrofit by sealing into a 13mm diameter hole. In operation the smooth mould side face is kept closed with strong magnetic force and operated to open with a strong tap to its base. Even thick and very rigid cured parts can be released.
"Superb! And works a treat on our new tooling! Saves on release agent application time and material cost also, as barely need to use wedges, which did tend to result in localised release application being required. Great product"- valued customer.
Marketed at below £20 each the company predicts the MAGLOC becoming the mould air ejector of choice.
EPOXY RESIN MOULDING BREAKS THE 100 MOULDING BARRIER
Prepreg use with Reusable vacuum bags is fine above 200 cycles but been abysmal for liquid epoxy resin until now. In extended trials report, New SILFLON allows re-coating of a worn out reusable bag and can give 100 PLUS epoxy mouldings to be produced from the same bag. SILFLON in addition to standard 125g is now available in larger 510g packaging. Just paint on - leave overnight and start moulding next day like new!
HOW TO SAVE MONEY WITH NEW TECHNOLOGY
We know you have an interest in composite moulding and possibly using either hand lay, infusion , RTM or prepreg in or out of Autoclave or are supplying these industries. The one single issue which binds us together is how to constantly improve and save costs.
We’ve been working now, for 5 years in creating ground breaking technology which allows big savings to be made in labour and materials to mould the most basic hand lay GRP cover or much more advanced prepreg wing sections of commercial airliners.
How this is achieved is based on the introduction of high temperature and robust self releasing vacuum membranes which are reusable up to 1200 parts as reported by some of our high output moulder clients.
Now there are some very worried suppliers out there who would give anything to dissuade you from even entertaining the idea of changing or increasing work with reusables as their continued business is based upon unsound but for them profitable business in continuing to supply consumables. Also we see major composite training and technical educational establishments not including in their curriculum the latest cost-saving technologies like this. The result is that many fully composite qualified new recruits entering industry are unfamiliar and ill-equipped in the latest art of moulding.
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NISSAN SERENA FRONT END produced in complex 8 part mould by VPI
CTIM – Leading Malaysian Auto body parts manufacturer chooses Vacuum Press Infusion for the new front end Serena MPV model from Nissan and tuned by Hoshino Impul Co., Ltd ,
Raymond Siew, CTIM’s managing director, said “the success of production moulding such a complex part in the closed mould VPI process has now led us to further development and production application many of our other auto aerodynamic parts. We achieve more consistency over our former hand lay operation with greater production speed and almost net size, low wastage moulding.” CTIM were trained in VPI by our Malaysian technical SIFT center led by TK Lim in Cheras, Kuala Lumpur.
We were pleased to recognise CTIM’s attention to detail and technical excellence in achieving series production, which in our opinion is one of the most complex closed liquid moulding composite parts we have ever witnessed. We were pleased to share and demonstrate our new MorphFlo™ technology with CTIM last week.
MORPHING RESIN FLOW RUNNER REVOLUTION
To infuse very high fibre content (circa 55%vf) has previously needed flow mesh , spiral wrap resin feeds and peel ply . Not anymore as optimised morphing runners (MorphFlo ™) eliminate all these costly and wasteful traditional flow enhancers . There are thousands of infusion moulders worldwide who will benefit from this innovation once they see it happening before their very eyes because just hearing about it sounds too good to be true. The system uses cleverly integral galleries behind the smooth and flat reusable vacuum membrane surface. These sealed galleries are pressure controlled to form resin highway networks distributing the resin very rapidly but made to morph flat, out of sight before the resin cures . No resin channel waste . No resin channel print through. No peel ply . No flow mesh, No spiral wrap.
Don't believe us? Come and see it for yourself. We promise you won't be disappointed.