CHALLENGING: THE LAMINATE PLAN
The laminate plan and the fabric requirements were developed in close cooperation with all SAERTEX locations. Based on many years of experience with composite parts, not only the density of the component was taken into account, but also the practical application. Due to the geometrically challenging shape, especially of the inner housing, special attention was paid to the draping process of the fabrics.
CONSTRUCTION WITH OPTIMUM MATERIALS: THE MOULDS
The molds were produced using a special polyurethane formula and CNC-milled from a block. This enables a cost-effective and easily customizable solution. The layout and all vacuum infusion requirements were worked out in close cooperation with the mold manufacturer, with whom SAERTEX has a long-standing business relationship. During the development phase, SAERTEX succeeded in milling the component in 5 axes.
INFINITE POSSIBILITIES: SAERTEX FABRICS
A combination of unidirectional carbon PES fibers and bidiagonal carbon fibers from SAERTEX was used for the outboard unit. The inboard unit was made from bidiagonal SAERTEX glass fibers. All fabrics for this project were custom-made at the headquarters in Saerbeck.
the best possible method: VACUUM INFUSION
The infusion concept for each individual part was developed using experience and previous tests with the respective tissues. Especially compared to an open mold process, no curing gases are emitted when using epoxy resin and vacuum infusion. The main reason for using vacuum infusion is the very controllable process with a specific resin-fiber ratio. This ensures high strength with optimized material consumption. Special challenges arose due to the composite structures and different thicknesses of some parts. Detailed documentation of the individual steps of the process sequence enabled a steep learning curve, which means that SAERTEX is very well prepared for all future series production processes.
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