A perfect combination: Transfer moulding and the FDC process

• Co-operation: Dieffenbacher and Arburg combine their expertise
• Potential: A new concept for hybrid lightweight parts
• Success: MoPaHyb project as initial spark

Lossburg/Eppingen, 26.09.2019

Dieffenbacher and Arburg, both family-owned companies from Baden-Württemberg, will in future cooperate to develop new solutions for the transfer moulding of hybrid components. This allows them to combine their expertise in the fields of press systems and automated presses as well as injection moulding technology, bringing together the advantages of both worlds.

Arburg and Dieffenbacher recently demonstrated their successful cooperation as part of the MoPaHyb research project “Modular production plant for heavy-duty hybrid components”, which was funded by the German Federal Ministry of Education and Research (BMBF). Together with Fraunhofer ICT, Pfinztal, and nine other partners, a modular production system for hybrid components was developed and realised. It combines a size 4,600 modular injection unit for fibre direct compounding (FDC) from Arburg with a Dieffenbacher 3,600-ton vertical press located at the ICT. The system makes it possible to implement component dimensions and complexities that could not be manufactured before.

“The subject of lightweight construction is an important one at Arburg,” emphasises Gerhard Böhm, Managing Director Sales at Arburg. “We offer various processes and solutions, including the FDC process. Combining it with transfer moulding is a forward-looking concept that enables new lightweight construction applications.” Manfred Reif, Head of the Composites Business Unit at Dieffenbacher, adds: “Based on the positive results achieved in the MoPaHyb project, we will in future also be offering Dieffenbacher transfer moulding presses in combination with an Arburg FDC injection unit. Together with our Fiberforge UD tape laying system and the Fibercon consolidation unit, we can offer our customers a strong overall package.”

Opening up new areas of application

Particularly for parts with very thin wall thicknesses, injection moulding offers a material-friendly and efficient manufacturing process. Geometric reinforcements in the form of ribbed structures as well as local or full-surface reinforcements using unidirectional tapes in combination with fibre-reinforced in-mould lamination open up numerous new areas of application, especially for structural applications. The advantage of using a Dieffenbacher press as a clamping unit is that reinforcing inserts can simply be inserted into the horizontal mould.

Arburg’s Fibre Direct Compounding (FDC) injection process allows fibres to be added directly to the plastic melt. The fibre length, fibre content and material combination can be adapted on an individual basis to influence the part properties in a targeted manner.

Presentation at K 2019

By combining transfer moulding and FDC injection moulding, hybrid components can be produced very economically and flexibly. Dieffenbacher will be presenting this concept at K 2019 in Düsseldorf from 16 to 23 October in Hall 14, Stand A02.

About Arburg

The German family-owned company Arburg is one of the world’s leading manufacturers of plastic processing machines. The product portfolio encompasses allrounder injection moulding machines with clamping forces of between 125 and 6,500 kN, the freeformer for industrial additive manufacturing and robotic systems, customer- and industry-specific turnkey solutions and further peripheral equipment.

An international sales and service network ensures first-class customer support at a local level: Arburg has its own organisations at 34 locations in 26 different countries and, together with its trading partners, is present in more than 100 countries. Its machines are produced exclusively at the parent company in Lossburg, Germany. Of a total of roughly 3,000 employees, around 2,500 work in Germany. About 500 further employees work in Arburg’s organisations around the world. Arburg has triple certification according to ISO 9001 (quality), ISO 14001 (environment) and ISO 50001 (energy).

Further information about Arburg can be found at www.arburg.com