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Honeycomb
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It is true that kg for kg composite materials may appear expensive but you actually need less mass. Very often the tooling costs of composites compared to sheet metal presses for lets say automotive panels are considerably less when looking at production runs of up to several thousands.
Even more weight can be saved and bending stiffness much increased once sandwich structures are utilised. That is a skin of fibre reinforced plastics (FRP) each side of a core material such as aluminium honeycomb or a structural foam such as PMI (trademark Rohacell). Once again we can have moulded shapes. Metallic sandwich structures are possible but usually are only flat or single curvature panels.
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Carbon Fabric
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With fibre reinforced plastics (FRP) the laminate can be tailored in different fibre directions and in the form of uni directional (aligned fibres) or fabric to suit stress paths. Also we can choose from a wide array of fibres that can be employed whether variables of high strength, intermediate and high modulus carbon fibres, Or others such as Aramid (kevlar), E- and S- glass, Zylon (PBO) Dyneema/Spectra (HDPE) and Boron. We can use hybrid fabrics of the aforementioned fibres and also mix materials within a laminate to utilise to the best advantage of the properties of each type of fibre.
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CAD Image
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Moldex is particularly proud of its Class 8 Clean Room dedicated to prepreg. laminating and vacuum bagging. With floor area of 120sqm, it is a fully temperature, humidity and dust controlled area, with an airlock entry/exit to restrict contamination.
A 1.5m diameter, 4.5m long Autoclave with a temperature capability of 220C and 10 bar pressure. This autoclave has state of the art full PLC programming & data recording.
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CNC 5 Axis
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There is substantial area for future expansion in addition to the area reserved for expansion on the ground floor within the 1600sqm facility. We have a dedicated Electric connection of a higher rating and our own step down transformer to allow for further expansion and higher power requirements, adequate fully automatic back up generators in the event of power failures, a heavy duty 10 bar compressor with storage tank and filters, a cooling tower for the Autoclave and proper secure facilities ensure minimum disruption to the production process.
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FEA Image
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For correct bonding preparation Moldex has a Vapormatt wet grit blasting machine. It is situated in a dedicated bond preparation workshop which is one of four interconnected workshops for trimming, assembly and finishing of patterns, moulds and components.
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