Design & Development

Material Development

Special applications require special materials.
Whether extreme environmental conditions, multi-axis loads or other complex requirements, we work with our network partners to design the ideal material for you that is precisely adapted to the requirements of your product.
Depending on the selected fibers, the layer structure and the wall thickness of the product, lightweight structures with almost any required property can be achieved. In contrast to conventional manufacturing processes and materials, complex geometries with undercuts are comparatively easy to achieve using fiber composite technology. Composites made of carbon fibers thus increase the scope for construction and design and therefore the power of innovation.

A special kind of surfaces

By selecting the appropriate material, different surfaces with the required fiber structure and surface quality can be produced, depending on whether the component is used in the interior or exterior.

Our Services:

Development of materials to implement customer requirements
Testing new materials and their combinations
Carrying out material tests, for example determining mechanical properties under different climatic conditions or testing fatigue strength
Improving the surface quality for Class A applications by using the latest in-mold coating technology.

Product Development

We design using state-of-the-art software and work closely with design and development departments. We work with the following CAD interfaces: UG, ProE, I-DEAS, STEP, IGES, VDA.

We use our many years of expertise to model and simulate designs and material composites and we check their suitability for the required application. Naturally, we always use the latest development methods. This often results in completely new advantageous design options for our customers, for example by using fillers or improving the design.

The focus is on short development times and few optimisation loops as well as on an economical production process.

Our Services:

Production-oriented design
Component design / FEA simulation (Finite Element Method)
Functional testing at part or component level
Carrying out tensile and compression tests, DMA, DSC or FVC tests
Development in accordance with IATF16949
Testing and development of recyclability
Evaluation of life cycle assessment / carbon footprint

Re-thinking design – weight saving with higher stability

Double-shell SMC construction

Part consists of an upper and lower shell, which are bonded together

Sandwich SMC construction

Part consists of a circumferential shell which is filled with a plastic core

Bench Test

A prototype is produced based on the new design

Computation

CAX tools are used to calculate and visualize load simulations such as reaction to stress and displacement on the part

Integrated Functionality

For special requirements, functional elements and reinforcements, damping, but also complex electrical wiring or sensors can be integrated into the semi-finished product before final production in the preforming process.
By using TFP (Tailored Fiber Placement) technology, the semi-finished product is also provided with reinforcing structures through technical embroidery.

Example of AMG GT wheel arches

Local TFP reinforcement, for example for impact protection in the wheel arch of a car

Example of AMG GT wheel arches

Multi-material composite with glass fiber preform, cork and metal inserts

Example of AMG GT wheel arches

Finished component

Process Development

Efficient production that meets the highest standards of quality and functionality is our goal from the very first step of process development. One of the decisive criteria when selecting the production process is therefore the quantity to be produced. We plan the tool design in line with this and develop and simulate production scenarios that are suitable for your product.

Our services: