Hybrid composite workcell supports thermosets, thermoplastics

Radius Engineering (Salt Lake City, Utah, U.S.), a supplier of equipment and tooling for closed-mold production of aerospace structures, is highlighting a hybrid composite workcell that can support both thermoset processes and thermoplastic processes. This equipment includes the capability to produce composite structures 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

The versatility required to support this range of processes is accomplished with the inclusion of a Double Acting-Distributed Pressure System (DA-DPS) press, multi-component injection system, a thermal oil temperature control unit and Radius’ Insights control system.  

The DA-DPS Press uses servo-electric actuation of the upper bolster for closing speeds up to 2.5″/sec and positional accuracy within ±0.001″. The up-acting lower bolster uses Radius’ DPS to provide even pressure within ±1 psi on tools as large as 4' × 6', with clamping forces 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-component injection system can operate with either premixed single-component resins or two-component resin systems with a heated on-demand mixing system. Resin volumes up to 31 L can be thoroughly degassed to less than 1 torr in the injection cylinders prior to injection at temperatures up to 350°F and pressure up to 160 psi.

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

All components of the workcell are 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 verification the cure cycle met all quality requirements. Insights can interface with factory ERP systems and material tracking systems to delivery Industry 4.0 capabilities.