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Press release  tl_files/MC1/pfeil_klein.png   update 18.03.2015

 

21.09.2015

Braiding technology of Munich Composites brings back production of CFRP components to countries with higher wages.

Munich Composites produces hollow components like field hockey sticks made from composites with its braiding technology in Germany.


Beginning this year, the company Munich Composites manufactures CFRP field hockey sticks in series production at its site in Munich, Germany. Up until now, hockey sticks were mainly made by hand in Pakistan due to low wages in Asia.  The advanced technology of Munich Composites now enables the production of these components in Germany.

The improved braiding technology of Munich Composites was the key to this development. The advantage of the process is that the components can be produced almost entirely automated. The braiding in which robots pull a mandrel through the braiding machine and the injection of carbon fibers with epoxy resin work completely without manual interaction. This way, the company can guarantee that each component has the same high quality.

Another cost advantage is the low amount of scrap of braiding compared to prepreg technology. In other technologies up to 40% of the expensive fibers are left as waste whereas Munich Composites has scrap rates of less than 5%. Therefore, this technology can not only be used for small series but also for mass production of high quality hollow components.

So far, the technology of Munich Composites has won several awards like the JEC Innovation Award 2012 and 2015. The technology has already proven to be excellent in practice. Today, Munich Composites produces several components in series for customers in different industries.

 

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Figure: Field hockey stick produced with the braiding technology of Munich Composites

 
 
18.03.2015
Munich Composites and MAN win the JEC Award 2015.

Carbon carrier for buses receives innovation award

The engineers of MAN and Munich Composites have won the JEC Award 2015 for light carbon-fibre spring carriers

The MAN Predevelopment Division joined forces with the carbon fibre specialist Munich Composites to develop an air spring carrier made from carbon fibre-reinforced composite material (CFC) for buses. The project was awarded the JEC Innovation Award Europe in the "Transportation" category.

JEC is the largest industrial association for composite materials. The award is used to distinguish outstanding developments made of fibre-reinforced composite materials and was handed over to the MAN developers Norbert Elbs and Susanne Rübsamen, and to Olaf Rüger and Martin Stoppel of Munich Composites, on 10th March at the largest carbon fibre industrial fair in Paris.

The aim of the joint project was to achieve significant weight savings for the rear axle beam with a length of approximately 1.60 metres. The current vehicle construction standard is to use steel beams. They are joined to the air spring suspension bags, which support the weight of the bus. Each rear axle has two air spring carriers, each with a weight of 83 kg. The carrying structure of the air spring carriers has a weight of approximately 53 kg. The prototype for this support structure with a CFC hollow profile is about 70 percent lighter and would thus increase the payload of a bus by one passenger. Following prototype development, the components now have to prove their road capability in stringent practical trials. In addition, economic efficiency also has to be evaluated.

At the same time the aim of the project was to develop a technology to manufacture such components on an industrial scale. At Munich Composites, the production process is highly automated: The carbon fibres are braided around a core with the aid of a radial braider. Several robots work together to pull the component core through the radial braider at exactly the right angles. The injection process for epoxy resin is also fully automated. It can thus be guaranteed that each component will be of the same high quality.

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Fotos: MAN and Munich Composites


About MAN

The MAN Group is one of Europe’s leading industrial players in transport-related engineering, with revenue of approximately €15.7 billion in 2013. As a supplier of trucks, buses, diesel engines, turbomachinery, and special gear units, MAN employs approximately 53,500 people worldwide. Its business areas hold leading positions in their respective markets.

 

About Munich Composites

Munich Composites GmbH is a company forbuild-to-order carbon fiber composite components. It offers all steps in the value chain from design to production of large series of braided hollow parts with its patented „BRAIDform“ production process. Parts in largequantities and complex geometries can be produced at a significantly lower cost with this technology. Munich Composites is based close to Munich, Germany. 

 
 
14.11.2014
Munich Composites wins Price for Innovation of Bavaria 2014

Great honor for young composite company: Munich Composites is credited for its production technology for hollow carbon fiber components.

The Bavarian Ministry for Economy, the Bavarian Chamber of Commerce and Industry, and the cooperation of the Bavarian Chambers of Craftsmanship honor companies that have developed great innovations once every two years. There were 189 companies nominated this year and six prices were awarded. Munich Composites won the price for excellent innovation in the category Start-Up for its technology of the automated production of hollow composite components.
 
Ms. Isle Aigner, Bavarian minister for economy and media, energy and technology, emphasized that innovation is the basis for the strength of the Bavarian economy and that it takes courage, effort, and sometimes also luck to succeed. The price acknowledges the leadership in braiding technology of Munich Composites. This technology guarantees a fully automated and therefore optimized lay up of the carbon fibers of every component. Using the innovations of Munich Composites, it is possible to produce small and large series of complex hollow CFRP components for a substantially lower price than with other technologies.
 
Tilmann Schöberl, moderator of the awards show, quoted George Bernard Shaw with the words “Some look at things that are, and ask why. I dream of things that never were and ask why not?”. “This price shows that we have always believed in our vision that is possible to produce hollow carbon fiber components automated and cost efficient”, says Olaf Rüger, Managing Director of Munich Composites. “Our happy customers of serial components are best proof that the market needed our technology. This price is a high motivation to continue to improve carbon fiber production technologies. We would like to thank the jury, ministry, and Chambers of Commerce and Craftsmanship.”
 
 
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Picture: Irmi Gessner

 

Munich Composites certified according to the ISO 9001 quality standard

Successful certification for the innovative composite company: Munich Composites continues its refinement of high quality standards by getting certified according to ISO 9001.

The quality management system of Munich Composites GmbH is now certified according to ISO 9001. This international standard documents that all processes and procedures in the company are subject to constant monitoring and therefore guarantees continuous improvement.
 
Olaf Rüger, Managing Director at Munich Composites GmbH: "With the QA certification, an independent authority has confirmed what we have already practiced on a daily basis. Our philosophy is to guarantee a constant high quality of every CFRP component. The certificate gives trust and credibility to our customers that they will permanently receive the highest possible quality level.”
 
In order to pass the ISO 9001 certification, companies must give proof that they operate according to an effective quality management system in all areas, including production, development, training, customer service, finance, and billing. All processes are documented and audited.
 
The audit verifies by an independent authority that the required process-oriented development and constant optimization of the quality management of our production is used for prototypes and series production.
 
The automated CFRP production of Munich Composites guarantees optimal placement of carbon fibers in every component. The certificate confirms that not only our production technology, but also our quality and service processes stand for absolute reproducibility.