SAERcore® RC for Tractor Roofs

Lightweight construction with maximum material efficiency

How can lightweight design be implemented efficiently and economically – without unnecessary material waste?

RealComposite provides a clear answer. Based in Mäntyharju, Finland, the company specializes in the design, manufacturing, and assembly of highly robust composite components. Together with SAERTEX, a solution was developed that goes beyond component performance and considers the entire material usage – with the goal of using resources as efficiently as possible.

"We wanted components that can be manufactured reliably while improving our material efficiency. Our goal was to produce efficiently – without waste and without compromising quality or performance."

Tuomo Nikkinen, CEO RealComposite Oy

At a glance

Project name

Lightweight composite tractor roofs made of SAERcore RC

Industry

Mobility & Transportation

Location

Mäntyharju, Finnland

Objective

Producing lightweight, durable components using reliable RTM processes - with 100% material usage

The idea

The focus was on developing tractor roofs for three model variants used in forest tractor applications. Key requirements included low weight, high structural performance, and consistent quality within the RTM process. To reliably meet these requirements, SAERcore RC was selected.

At the same time, material usage was reconsidered. Production offcuts are not treated as waste but are reused in separate applications. One example is the production of additional GRP components such as weather stations (radiation absorption units).

The applications themselves are independent. The common link is the process approach: use materials as efficiently as possible and avoid waste.

Technical advantages

Reduced component weight lowers energy consumption in forest tractor operation

Up to 50% faster resin flow reduces injection and cycle times compared to previous core materials

Excellent drapability enables reliable processing of complex geometries

Uniform mat thickness ensures consistent part quality and improved surface finish of the final components

Production offcuts are reused → maximum material usage, minimized waste

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How SAERTEX^® reinforced this idea

For manufacturing the tractor roofs, Real Composite relies on SAERcore® RC.

The material design, combining CSM layers with an integrated flow zone, enables fast and uniform resin distribution in the RTM process. This leads to shorter injection times and more stable processing compared to previous core materials.

At the same time, the uniform thickness of SAERcore RC further improves process reliability across all parts and results in a visibly better surface finish. Moreover, its excellent drapability simplifies handling during lay-up and allows safe processing of more complex geometries.

A key aspect of this product variant is the core material itself. SAERcore RC is made from 100% recycled core materials. This reduces the carbon footprint while improving product properties and process reliability. Combined with the reuse of production offcuts, this creates a comprehensive approach to efficient material use in manufacturing.

The success story

The developed tractor roofs meet the requirements for weight, durability, and process reliability in RTM production – across all model variants and under real forest tractor operating conditions. Manufacturing is efficient, reproducible, and designed for stable cycle times.

The project also demonstrates how material efficiency can be optimized throughout the entire production process. Production offcuts are systematically reused for additional GRP components such as weather stations, reducing waste and improving overall resource efficiency.
Furthermore, the final roof components can be easily cut using a robotic waterjet cutter, resulting in clean and high-quality edges without water penetrating the reinforcement fibers. These cut-out pieces can then also be reused in secondary applications such as jigs.

Together, this creates a manufacturing approach focused on maximum material usage, reliable processing, and long-term resource efficiency - a truly sustainable approach.