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Reinforced plastics: High-performance material for lightweight construction
Various sectors rely on lightweight design components to reduce fuel consumption and weight. For the aerospace, automotive, caravan and rail industries, lightweight is an integral part in series production. These are the sectors for which Langzauner Perfect from Lambrechten (Upper Austria) designs its custom-made composite presses:
High-performance plastics – composite
| Abbrev. | Full name (English) | Typical automotive applications (fiber-reinforced / matrix) | Typical aerospace applications (fiber-reinforced / matrix) |
|---|---|---|---|
| PP | Polypropylene | GF‑PP for front-end carriers, bumper beams, instrument panel carriers, fan shrouds, door modules, interior trim parts. | Mostly simple interior panels or secondary parts, rarely highly loaded structures. |
| PA6 / PA66 | Polyamide 6 / Polyamide 66 | GF/CF‑PA for structural modules (pedal brackets, front-end carriers), housings, coolant and air ducts. | Technical parts, clips, brackets and fasteners with higher temperature and media resistance. |
| PPS | Polyphenylene sulfide | High‑temperature engine compartment parts, pump housings, connectors, e‑mobility high‑voltage electronics. | Structural and system components with high temperature and chemical resistance. |
| PEEK | Polyether ether ketone | Highly loaded bearings, bushings, seals, performance/motorsport parts, electrical and electronic components. | CF/PEEK tapes and laminates for structural parts, clips, brackets, mounts, bearings and housings. |
| PAEK | Polyaryletherketone (family) | High‑performance parts similar to PEEK/PEKK, e.g. structural parts, gears, pumps, e‑powertrain components. | CF/PAEK tapes and organosheets for primary/secondary structures, clips, ribs, stringers, brackets. |
| PEKK | Polyether ketone ketone | High‑temperature and FST‑critical parts, especially in E&E and specialty vehicles, metal replacement. | CF/PEKK structures such as pylons, stringers, shells; interior and structural components with high FST. |
| LMPAEK | Low‑melt polyaryletherketone | Niche material where lower processing temperatures for complex CF tapes/organosheets are beneficial. | LM‑PAEK CF tapes for fast AFP/press forming of primary and secondary structural parts. |
| PEI | Polyetherimide | Connectors, E&E parts, heat‑resistant housings and brackets in the engine compartment. | Aircraft interior parts (seat structures, panels), ducts, electrical components with FST requirements. |
| PSU / PPSU | Polysulfone / Polyphenylsulfone | High‑temperature connectors, fluid components, pump and valve parts. | Lightweight parts with high temperature and impact resistance, e.g. covers, brackets, fluid and connector systems. |
Every composite press from Langzauner Perfect is made to measure and designed in close consultation with our customers. The perfect implementation of individual processes in the production of lightweight construction components is our speciality.
Short cycle times are fundamental
The processing of composite materials (carbon fibre, glass fibre, natural fibre, thermoplastic) requires short cycle times to bring the preheated material into the press to be shaped. Automated solutions from Langzauner ensure that you won’t lose any valuable time.
Step 1: Consolidation
In the first step, the organo sheet is consolidated. Skilled tempering is performed in the press via heating plates and a high-precision cooling cycle. Langzauner Perfect offers electrical heating plates as well as water cooling or the use of thermal oil. The end of the process provides the semi-finished product in the form of an organo sheet.
Step 2: Forming
In the forming process, a transfer unit (linear axis transfer or robot) quickly transfers the organo sheet from the infrared preheating station to the press. Forming in Langzauner presses is performed in less than 5 seconds (incl. the build-up of pressure). Thanks to the unique servo-hydraulic drive, the press itself works with maximum precision and extremely energy-efficiently. To ensure perfect parallelism, the cylinders are controlled individually.
Advantages of our composite presses
- Hydraulic press systems up to 100,000 KN
- Servohydraulics for high accuracy and energy efficiency
- Infrared heating (IR), infrared oven
- Automatic transport shuttle systems
- Robot and gripper equipment for loading and unloading
- Single or double shuttle table
- Heating and cooling systems
- Heating plates and cooling plates up to 450 °C
- Material handling
- Vacuum systems
- Software with full traceability
- Data backup
Turnkey presses for composite materials
As a specialist for composite presses and production processes, Langzauner Perfect from Lambrechten (Upper Austria) works as a turnkey provider:
- Joint definition with the customer: Feasibility study and concept development
- Engineering: Construction & detail design
- Turnkey handover: Logistics, assembly and start-up
- Service: Maintenance & inspection of the composite press
Customers from the field of aerospace technology and the automotive, caravan and rail industry value the continual support provided by Langzauner Perfect.
