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Competencies

You have the idea- we’ll shape it!

Benefit from our established know-how in development, production and examination of fiber-reinforced composite parts, complex ready to install modules as well as electric and electronic system components. The long-term experience, widely varied professional expertise and comprehensive technical equipment provide the ideal prerequisites for holistic development, project support and mass production of suitable light-weight fiberreinforced composite structures from sophisticated casing parts to highly-loaded large components. Our parts are distinguished by complex geometries, diverse specifications and a reproducible high quality. The high technology competency which is used in the production of light-weight fiber-reinforced composite structures (RTM, vacuum infusion, Prepreg, hand laminating and SMC presses) as well as in the assembly of complex systems allows us to produce in different volumes and depths.Engineeringcenter

Engineering

We have a proactive approach to develop outstanding solutions for our customers. Our engineering team with experts from construction, process technology and composite technology traces the development process from the first idea to the stable mass production and provides you with complete solutions from a single source.

Parts development/ construction

  • Complete 2D and 3D construction of components, assemblies and the complete systems.
  • Suitable composite construction of lightweight components with function, stress and processing adjusted feature characteristics.
  • Design drafts and concepts for interior and exterior parts. -Development of economical and intelligent molding tools. -Construction of parts-
  • adjusted transport racks and production devices.
  • Development of mechanisms and kinematics as well as connection technologies (e.g. connections to the vehicle body).
  • Suitable fiber-reinforced design by means of most modern hardware and software: ProEngineer Wildfire 5.0, Catia V4/V5, Autodesk Inventor, AutoCad and Creo Simulate (FEM).

Development of process technology and material

  • Development of fire retardant systems (combined system of core material, reinforcement material, resin, Gelcoat, paint) in order to fulfill the latest international rules (e.g. EN45545-2)
  • Development of function-integrated fiberreinforced molding tools.
  • Development of heatable glass-fiber reinforced composites.
  • Structure and material development with extreme light-weight requirements (-30% weight) and stipulations: fire prevention, efficient small-series production and vandalism resistance and safety.
  • FEM calculations for design and optimization of glass-fiber reinforced composites with respect to light-weight and cost-efficiency.
  • Comprehensive material and components tests with respect to long-term use, static and dynamic stress, temperature effect (e.g. climate change test), bullet resistance as well as sand and dust stress.
  • Development of customized surfaces (e.g. granite effect) on glass-fiber reinforced composite materials to be used in flooring, sinks or similar areas.

Process

Handlaminierung

Hand lay-up

Due to the low investment costs, this process is especially appropriate for small – series production. Currently small parts (e.g. interior linings) and also structure components (front nose, front structural) are produced in accordance with international fire prevention rules. The limits of this process substantially depend on profitability with high quantities, components geometry and the achievable mechanical laminate properties.

SMC Heisspresse 2.500 Tonnen

SMC-Hot pressing

This process is a closed process which particularly is appropriate for mediumsized to bulk production (>1000). In low cycle times, it allows components with constant wall thicknesses and geometrically complex details to be produced which fulfill the current fire prevention requirements. The raw material is thereby a fluid prepreg on UP resin basis. To be noticed is the maturity time, due to the latent hardening of materials under temperature.

RTM Verfahren Einlegen von Glasfasermatten

RTM (Resin Transfer Molding)

This process is a closed one which pays itself off from production of 100 pieces onward. Through injecting thermosetting composites in the cavity, high quality glass-fiber reinforced composites are produced efficiently and environmentally friendly. The tools consist of glass-fiber reinforced composites and supported by means of solid steel substructure. With this process glass contents up to 30% can be attained, if special semi-finished glass which enables resin flow despite highly-filled fire protecting resin systems, is used.

The limits of this process depend on respective individual cases, however they generally depend on component geometry, minimum number of pieces and dimensions of the component.

RTM-Verfahren_Injektionsarbeitsplaetze-2

RTM-light

This is the light version of RTM process. It is different from the previously described RTM process in this way that here we only have low injection pressure but there is vacuum support. In this process the tool, consisting of female and male, is closed by means of a revolving vacuum ring. This process has the comparable advantages as RTM, however with improved handling and price benefits.

Prepreg Verfahren Vakuum

Vacuum infusion

This process is a closed one which is especially appropriate for small-series production (<40). The investment costs for this process are lower than RTM because only a one-sided molding tool is necessary. Here the laminate, instead of a solid male (see RTM), is consolidated in through a composite foil on which a vacuum is fitted. Through the existing resin and vacuum gates, the resin is sucked in by means of the physical principle of pressure balance. This way the glass content of 40-55% can be nurtured by which compared to hand lay-up a better mechanical properties can be reached.

Prepreg Verfahren Frontkabine FLIRT

Prepreg- parts manufacturing

The Prepreg technology is particularly appropriate for parts with highly low-weight construction and strength requirements. Fiber contents of 50% can be accomplished. The raw material is a Prepreg on epoxy resin basis which polymerizes under the influence of temperature and pressure (vacuum foil). Like SMC, here also a limited storage time is available which is prolonged by freezing. The lowtemperature Prepreg-system which is specifically developed for rail vehicle construction, fulfills the fire retardant requirements in accordance with international standards.

Products

Our products

We, as a successful medium-sized company, provide you with the optimal solution for your needs. Our concepts are based on experiences as a supplier of systems and components in rail vehicle construction industry.

  • Casing parts
    (interior and exterior)
  • Front masks, head modules
  • Lavatories
  • High speed components
  • Locomotive roofs
  • Assembly of electric and electronic components
  • Indoor unit with display and information modules
    (e.g. destination display, information module)
  • Driver’s cabin/ module
    (e.g. Driver’s display, train radio system, brake switch, controls, signal lamp)
  • Control cabinet for the vehicle body
    (e.g. SPS- Vehicle steering, vehicle bus gateway, EDC- steering device for diesel engines, gearbox steering)
  • External module
    (e.g. sensors, kinematic, peripherals, solenoid valve)