At FAKUMA 2017, we presented the latest developments in our extensive spectrum of plastic processing technologies. Under the motto HIGH TECH AND HIGH PASSION, visitors experienced virtual 3D full-scale FRIMO systems for PU processing, including flexible trimming, punching, pressing/forming, thermoforming, press laminating, edge folding, ...
FRIMO at JEC World 2022 in Paris
We are back again! Live and in color! After JEC World 2020 was cancelled due to the pandemic and held purely digitally last year. That's why we are very pleased that in 2022 the world's leading International Composites Show will be held again this year live in Paris-Villepinte from May 3 to 5. Of course, we as the FRIMO Group will present ourselves again as a tool and equipment supplier for complete solutions in the field of composite applications. We look forward to welcoming you at JEC World 2022!
FRIMO offers an exceptional range of technologies and services. We accompany customers in every single process step: Whether high-quality tools, high-performance individual machines or fully automated production lines - FRIMO always offers an individually optimized solution. And that worldwide! As an innovative technology partner, we supply a complete product range, from PUR- or epoxy processing, flexible trimming, thermoforming, punching, pressing and forming, to welding processes.
We are also the right contact for you as a company that want to think outside the box and implement innovative, sustainable product ideas. Some examples of such projects are certainly among FRIMO's trade show highlights this year.
Below you find an overview of our topics at JEC World 2022:
Innovative upholstery material
An innovative 3D structure made of elastic polyester continuous filaments offers itself as an alternative for seat cushion production. The recyclable BREATHAIR® product from PHP Fibers is highly water repellent, antibacterial and exceptionally permeable to air and moisture. Breathair is already used, for example, in geometrically simple mattresses but also in seat cushions of the Japanese high-speed train Shinkansen.
With the aim of giving this environmentally friendly product more complex geometries, for example for automotive seat posts or the furniture industry, we have developed an innovative processing method in collaboration with PHP Fibers. In this process, the primary material, which is cut into a cube shape, is inserted into a mold and shaped to the exact contour by a sophisticated heating, forming, and cooling process, while optimally maintaining the elastic yet sufficiently rigid loop structure. "It is a real challenge to heat this material evenly and to form and cool it down again quickly," says Thomas Joachim, Director of Sales of the FRIMO Center of Competence Form & Punch. In addition, the integration of further functions, such as molded-on or pressed-on holders for seat covers, etc., in conjunction with corresponding textiles, allows the production of single-material systems. These thermoplastic single-material systems are comparatively easy to recycle, entirely in line with circular economy efforts.
Pallets from coconut fiber
In Asia alone, around 170 million trees are cut down every year for conventional disposable pallets. Last but not least, wood is one of the raw materials currently affected by supply and price problems. Forests do not grow in a year, and these shortages cannot be fixed anytime soon. This wood is better off being used for long-term purposes such as furniture and construction.
The Dutch startup CocoPallet offers a sustainable alternative with novel disposable pallets made from coconut waste. In a processing method specially developed by us for CocoPallet, the powdered and fibrous waste from coconut husk is compressed under pressure and heat to form sturdy pallets. In the process, the coconut fibers are bonded only with the naturally contained lignin in such a way that no additional substances need to be added. We at FRIMO has been supporting the startup company for several years. Now, together with CocoPallet, a special filling and dosing system and a prototype tool to produce these innovative stackable pallets have been developed. In addition, the pallets are recyclable but also biodegradable. Building on the success of the pallets, CocoPallet is already planning to use the process for other applications.
Wet compression molding
For the production of fiber-reinforced structural components in automobiles, we offer fully automated systems for wet compression molding of monolithic and sandwich components. In this process, dry continuous fiber layups or fabrics are impregnated with a reactive resin outside the press, then brought into the press and consolidated there, where the matrix materials cure.
The lower process pressures compared to RTM make it possible to combine the fiber composite structures in the pressing process with sandwich cores, for example made of foamed polyurethane or polyethylene cores, or paper honeycombs in a single step. In addition, more cost-effective tools can be used and cycle times can be significantly reduced. Another advantage WCM has over RTM is the elimination of three-dimensional preforming of the fiber structures in advance.
Joint project “LightMat Battery Housing”
The trend towards electric cars leads to a strong focus on the whole battery package. The aim of the joint project LightMat Battery Housing (EFRE-0801511) is to develop functionalized, unidirectional fiber-reinforced semi-finished products for high volume production of highly stressed lightweight plastic battery housings. For the battery housing, this translates to a significant weight reduction compared to today's e-vehicles with maximum functional integration in terms of stiffness, strength, EMC shielding, fire protection and process flow. FRIMO is contributing with its expertise in developing special tooling and process technology for UD and D-LFT Tapes.
UD-tapes are continuous fiber-reinforced thermoplastics that offer the most mechanical properties in fiber direction. Direct long fiber thermoplastics (D-LFT), however, provide more design freedom because of their good flow behavior. When both are combined and metal inserts are added, a new degree of freedom is reached and the lightweight potential for hybrid structures can be better utilized. Combining different materials creates special requirements for tooling. We have developed a special tool concept for this. In this concept, the pre-heated, compressed UD tapes (tailored blanks) along with the D-LFT strands are placed in the tool cavity and compressed with precision-controlled advancing pins. The advancing pins in the FRIMO Tape-D-LFT tool drape the "tailored blanks" and form the rib structure cavity to be locally overflowed with D-LFT. The additional tool closing movement presses the D-LFT into the ribs. The FRP/metal mixture makes weight savings of up to 25% possible compared to a steel construction, with a cycle time of less than a minute. This doesn't just turn into weight savings, but also time and money savings.
Complete value chain
In addition to the highlights mentioned above, we will also present our expertise and experience in thermoforming, milling, punching, and joining of composites, as well as in the automation and interlinking of processes and equipment at JEC World 2022.
We offer more than just tools, machines, and equipment in a technology portfolio that is unique on the market. Our customers also benefit from the comprehensive consulting expertise of a technology company that is the market leader in many fields. This ranges from initial consultations and pre-engineering to completely customized concepts. Companies that think sustainably and want to participate in implementing a Circular Economy will find competent, creative contacts at FRIMO.
Supported by global sales and project management, we continue to stand for One Stop. All Services along the entire value chain.
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Thank you to everyone who came out for our FRIMO Mexico Grand Opening and TechDay, especially our two guest speakers, Fidel Vaca Reyes from Faurecia and Karl-Heinz Stump from BMW. We had a great time celebrating the opening of our plant with you and look forward to continuing our work together in the future!