Preform for a Boat Deck

Lampshade and Preform

Directed Fiber Preform Sample- (Click for Larger Image)

Directed Fiber Preforms:

    Composite Factory has developed a unique Directed Fiber Preform process, producing  significant improvements in preparation of a preform as well as in closed molding performance:

• Very Short cycle times - under 90 seconds per part - button to button - Regardless of part size!

• Excellent resin flow characteristics from low binder content

• Tough, but flexible preform is produced - easily conforms to mold shape

• Preform does not require additional fitting or adjustment to mold

• (Complete Specifications and benefits)

This flexible system is produced by our exclusive equipment and thermally set dry fiber binder, and handles any number of popular fiber types, including E-glass, Aramids, Carbons, Ceramics and others.  Additionally, multiple fiber types may be run at the same time, including veils, increasing structural optimization of the reinforcement.  The process also easily allows further structural optimization by easily programming certain areas with higher or lower aerial densities.  The efficient use of material in this process along with the use of economical fiber stock provides excellent value for high volume part production (greater than 500 parts) while still providing affordability for low volume and prototype projects.

Processing:

These preforms have been used in many medium and high volume applications including:

• Automotive Bumper systems

• Recreational boat components - Decks, housings, etc.

• Lampshades

• Chemical Drain sumps

Typically for most applications, the lowest cost raw materials (toe or roving) are used to keep costs down.  Although not providing the same ultimate strength of unidirectional type architectures, random fiber architectures (like our directed fiber preforms) provide excellent strength and tailored mechanical properties throughout a single composite part, yielding a highly engineered and optimized composite structure at a truly affordable cost.  

Some advantages of the directed fiber preform include the ability to make preforms with over 50% glass loading that have higher shear properties than any equivalent composite (same resin).   The preforms have superior wet-out characteristics versus woven reinforcements which means they are ideal for SRIM, VARTM, or RTM and you can still be certain of wetting-out the fibers, not just encapsulating them.

Availability:

Composite Factory offers complete services to support the integration of this preform technology into your manufacturing process:

• Prototyping of preforms in your material systems and to your density specifications
• Trial and development services for prototype molding, including on-site support
• Low cost tooling and low set-up charges for production runs
• 100% customer satisfaction for production deliveries
• JIT deliveries from our facility
• Availability to integrate the Shuttlegate machine into your facility

Please contact Bob Vorabetz for pricing and technical consultation of your molding issues.

Preform Manufacturing Equipment:

Composite Factory has developed unique processing equipment for the production of our directed fiber preforms, and offers the "Shuttlegate" machine for Lease or Sale to provide you with integrated preforming capabilities for your molding process.

The automated preform technology, or Shuttlegate Preform Machine, represents a leap in manufacturing efficiency for the composites industry.   The preform machine is computer controlled and can produce precisely repeated fiber placement in complex shaped preforms.   The system uses a binder fiber, produced exclusively by Composite Factory, that results in a dry preform which only requires a low temperature heat curtain to set the preform shape.   Because the binder is not a liquid or a powder it sets more quickly, provides a more consistent part and since less binder is used, improved resin flow characteristics result.

The preform machine is substantially faster than its nearest competitor and has produced parts as large as 8 feet by 10 feet.   The size of the final component is only limited by the size of the tools and the molding method, not by the preform size.   The preforms produced by this method can be stacked and combined to produce even larger preforms.  

The preform machine was used to produce structural bumper beams for GM at rates of one every 45 seconds.   These parts were engineered for reduced weight while maintaining strength and precise failure characteristics.   Multiple detailed energy management zones were implemented in the bumper beam preform by varying the glass loading throughout the part creating both high deflection and high rigidity zones in a single step process.   The preform process was the lowest cost method of producing the bumper beams and replaced the thermal formable fabric process. 

Please contact Bob Vorabetz for more information about this equipment, the cost savings and quality improvements which may be realized for your process.

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