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FIBERFORGE® sells custom composite sheet goods, finished parts, and manufacturing solutions to customers in the rapidly
expanding, thermoplastic advanced-composites market. Our patented automated layup and thermoforming system enables the
AFFORDABLE PRODUCTION OF LIGHTWEIGHT ADVANCED-COMPOSITE STRUCTURES.
FIBERFORGE ADVANTAGES:
• Lightweight
• Low scrap
• Recyclable
• One-minute cycle times
• High structural performance
• Low cost
Fiberforge works closely with
customers to develop and
implement solutions that readily
scale-up and meet high-volume
production requirements.
L i g h t w e i g h t : Weight is a critical factor in many products designed and produced today.
Fiberforge composites are superior to injection molded thermoplastics, sheet molding compounds, glass
mat thermoplastics, stamped steel, stamped aluminum, and carbon-fiber reinforced textile sheets for
lightweighting—as illustrated by the specific properties in the above charts.
Injection Molded
Glass/Nylon
Sheet Molding Compound/Glass Mat
Thermoplastic
StampedSteel
StampedAluminum
Carbon/Nylon Reinforced
Textile Sheets
FiberforgeCarbon/Nylon
Specific Tensile StiffnessSpecific Tensile Strength
0 2 0 0 4 0 0 6 0 0 8 0 0
MPa/ρ
0 2 0 4 0 6 0 8 0
GPa/ρ
The Fiberforge solution embodies all of the best features
of advanced composites while overcoming traditional
processing limitations. This solution uses automated,
high-speed machinery to obtain:
� LONG FIBER LENGTH
� HIGH FIBER ALIGNMENT
� HIGH FIBER FRACTION
Fiberforge’s results speak for themselves:
� 200% TOUGHER than epoxy-based composites
� 500% STIFFER than injection molding materials
� 60% LESS SCRAP than textile sheets
� 60-SECOND cycle times for forming
� 60% LIGHTER than steel
T H E F I B E R F O R G E P R O C E S SThe Fiberforge process uses automated machinery to layup flat tailored blanks that approximate the outline of the final
part. The machinery precisely orients each strip of material to give the final part its intended mechanical properties with
the least total amount of material. Following layup, the tailored blank passes through an optional consolidation step.
Next, the tailored blank is thermoformed, where the blank is heated and then transferred into a press where it is
stamped into its final shape. Lastly, the part is trimmed of any extra material.
LENGTHOF FIBERS
S H O R T L O N G
ALIGNMENTOF FIBERS
FIBERFRACTION
Loads are passed from fiber to fiber through the matrix—matrix
properties dominate thepart properties
Loads are carried mainly by the fibers—part properties
benefit greatly
Loads are carried along the fiber direction—partproperties benefit greatly
High fiber fraction dramatically improves part
stiffness and strength
Loads flow between and throughfibers with which they are
aligned—many fibers go “unused”,wasting fibers and hurting
performance
More matrix, less fiber—partproperties are weighted
toward the matrix properties
R A N D O M C O N T R O L L E D
L O W H I G H
GOOD BEST
GETTING THE MOST OUT OF HIGH PERFORMANCE FIBERS
EXAMPLE: FIBERFORGE SEAT FRAME FOR JOHNSON CONTROLS’ GENUS SEAT CONCEPT
SHOWN AT THE 2005 NORTH AMERICAN INTERNATIONAL AUTOMOTIVE SHOW
Johnson Controls (JCI) is a leading automotive Tier-one supplier of vehicle interiors, seating systems,
and batteries. The Genus prototype offers leading-edge features and technologies and embodies
JCI’s vision for the future of automotive seating. It incorporates new materials designed to improve
comfort and it features an innovative design: a thin, lightweight structure; a cantilevered base; and
TT AA II LL OO RR EE DD BB LL AA NN KK SSFiberforge has invented and patenteda novel approach to producing high-performance composites in highvolume. The process createsstampable advanced-compositeTAILORED BLANKS without costlyintermediate materials forms. Thestarting materials range from large-tow continuous or long-discontinuoustechnical fibers and neatthermoplastic resin to pre-impregnated thermoplastic tapes.Fibers include carbon, glass, andaramid, while resins include PA, PEEK,PEKK, PC, PP, PPS, PE, and PBT.
Frame
IR-Heating
Tailored Blank
CONSOLIDATEDTAILORED BLANK
TAILORED BLANKLAMINATION
0
0
90
-45
+45
90
90
90
90
-45
+45
90
FIBERFORGE’S AUTOMATEDTAILORED BLANK SYSTEM
“active” comfort features. Its design provides more cabin space and reduces overall system mass.
The Genus is the first concept to feature a thin overall profile and an exposed composite structure.
This cantilevered structure enables the seat to be raised, suspended on its base unit, and integrated
into the vehicle’s floor pan. Fiberforge supported JCI’s design, analyzed the seat frame for structural
performance, and manufactured several prototype frames.
Pressure
Mold
FinishedPart
Automatic Transfer
THERMOFORMINGOF TAILORED BLANK T H E R M O F O R M I N G
Thermoforming tailored blanks is the
best way for designers to capture the
potential of advanced composites.
Parts can be rapidly formed with low
scrap using TAILORED BLANKS made
from pre-preg tapes or “raw”
materials all while maintaining
length, alignment, and fiber fraction.
Thermoformed composite parts can
be post-processed in many ways to
integrate them into structural
applications.
THERMAL ANALYSIS
FINISHED PART
D E S I G N A N D D E V E L O P M E N T C A P A B I L I T I E S
Fiberforge maintains a design and development capability to assist you with your application of the Fiberforge manufacturing process. Up-front
we can assist with part design, matrix and fiber selection, lamina orientation, and analysis. Fiberforge can design and acquire prototype, short-
run, and production molds. Within the Company’s pilot manufacturing cell, we can produce prototype and short run production parts under
1-meter square and 200-millimeter depth of draw. Once you have adopted the Fiberforge process, a production and supply plan for tailored
blanks will be customized to suit your needs. Contact us for more details—our contact information is on the rear cover.
B E N E F I T S O F F I B E R F O R G EHIGH STRUCTURAL PERFORMANCETo justify the use of advanced composites, applications should be highly stressedstructures where stiffness and/or strength are critical properties. Primary orsecondary structures are good examples. Fiberforge’s specific performance isgreater than stamped metals’ and woven composite textiles’ commonly used inthese applications (see chart on first page).
MANUFACTURING VOLUMEBecause the Fiberforge process uses thermoforming to translate a two-dimensional tailored blank into a three-dimensional finished part, the cost ofpress molds must be factored into the fully-burdened part cost. Whilethermoforming molds cost significantly less than steel stamping tools, their costcan constrain the lower bounds of economic production. However, there aremany practical and emerging low-cost mold options that can be used forprototype and/or short-run production.
SECONDARY FORMINGThermoplastics can be post-processed and have tremendous design flexibilitywhen combined with additional thermoplastic forming processes like injectionovermolding.
INSERTS, CORES AND JOININGAdvanced composites similar to the ones made with the Fiberforge process havebeen produced for many years and many solutions exist for inserts, cores, meltwelding, and joining.
COSTCost is very dependent on fiber and polymer resin selection, production volumes,tooling requirements, and post-processing. Therefore, we ask that you contactus to discuss your application. You will find that compared to the competition,Fiberforge delivers significantly higher value.
Tailored Blank
Formed Part
Overmolded Part (source: EPFL)
Fiberforge delivers thermoplastic composite solutions. Our vision is toenable the growth of thermoplastic advanced composites into newmarkets. Together, Fiberforge and our customers will realize this vision ofhigh performance and low cost.
TTOO AACCHHIIEEVVEE HHIIGGHH PPEERRFFOORRMMAANNCCEE:: � SPECIFY long technical fibers� ALIGN the fibers� ENSURE a high fiber fraction
T H E F I B E R F O R G E S O L U T I O N
TTOO AACCHHIIEEVVEE LLOOWW CCOOSSTT:: � MINIMIZE scrap� USE engineering thermoplastics� EMPLOY high-speed processing� AUTOMATE blank layup� TAILOR fiber orientation
FIBERFORGE®
3768 Highway 82
Suite 204
Glenwood Springs, CO 81601
USA
Phone: +1 (970) 945-9377
Fax: +1 (877) 232-0292
Email: info@fiberforge.com
Web: www.fiberforge.com
©2005 Fiberforge
Fiberforge is looking for development partners and
tailored blank customers. If you are a designer,
materials supplier, molder, or manufacturer looking to
create breakthrough products, capture new markets,
and increase margins, we invite you to contact us to
learn more about Fiberforge.
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