Hybrid composite workcell supports thermosets, thermoplastics

Radius Engineering (Salt Lake City, Utah, U.S.), an equipment and tooling supplier for closed-mold aerospace structures, is featuring its Hybrid Composite Workcell to support both thermoset and thermoplastic processes. The equipment will produce composites with the following processes:

• Thermoset processes
  • Resin transfer molding (RTM)
  • Same qualified resin transfer molding (SQRTM)
  • Compression resin transfer molding (CRTM)
  • Compression molding
• Thermoplastic processes
  • Consolidation
  • Stamp forming

This distinctive versatility is accomplished with a Double Acting-Distributed Pressure System (DA-DPS) press, multi-component injection system (Multi-K), a thermal oil temperature control unit and Radius’ Insights control system.  

The DA-DPS Press uses servo-electric actuation for fast upper bolster closing speeds of 2.5″/sec and positional accuracy of ±0.001″. The up-acting lower bolster uses Radius’ DPS, providing an even pressure of ±1 psi on tools up to 4' × 6', with clamping up to 325 t. The press can be configured in six standard sizes for tooling as small as 2' × 2' and as large as 4' × 12'.

The Multi-K injection system operates with either premixed single-component resins or two-component resin systems and a heated mixing system. Resin volumes to 31 L can be rapidly degassed to less than 1 torr in the system prior to injection at temperatures up to 350°F (180°C) and pressure up to 160 psi (11 bar).

The temperature control unit (TCU) provides 144 kW of heating with a maximum operating temperature of 650°F (470°C), and a 100-kW heat exchanger which can achieve tool heating rates greater than 5°F/2.8°C per minute.

The Workcell is controlled and monitored by Radius’ Insights control system. Insights is a supervisory control and data acquisition (SCADA) system that can control all process parameters, provide instructions to operators for manual actions, log data continuously and analyze the data for verifying the cure cycle meets all quality requirements. Insights can interface with factory ERP systems and material tracking systems to delivery Industry 4.0 capabilities.