fast furious foamed rohacell® triple f 3d foam cores

FAST FURIOUS FOAMED

ROHACELL ® Triple F 3D Foam Cores

Mr. Werner Stoeger

FAST FURIOUS FOAMED

3D foam cores

for high volume production

of composite components

in superior product quality

An attractive company

LiteCon GmbH 3

• Joint Venture of Evonik Industries AG and SECAR Technologie GmbH

• Location: Hoenigsberg / Austria

• Production area: 2.000m²

• Start of Production: May 2014

• Certifications:

ISO 9001 and Part 21G

Evonik Industries AG

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• Evonik is one of the world’s leading

specialty chemicals companies

• Production sites in 25 countries,

active in over 100 countries

• 2014: 33,000 employees

Sales of €12.9 billion

Export Rate: 78%

• Producer of ROHACELL®

ROHACELL Triple F®

SECAR

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• SECAR is a highly specialized

manufacturer of composite parts:

Automotive, Aerospace, Medicine, etc.

• Foundation in 1998

• Privately owned

• Turnover in 2013: EUR 8.5 Mio.

• Employees: 65

• Certificates:

ISO 9001 | EN 9100

ROHACELL Triple F®

Why using ROHACELL® foam cores?

Sandwich construction leads to the lightest available final parts.

ROHACELL® Triple F offers superior material

characteristics with high design freedom.

ROHACELL® Triple F can also offer significant

cost reduction in mass production.

Why using ROHACELL®?

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Processing

Logistics

In Service Performance

Design

Homogenous and isotropic material behavior

Design freedom: complex, integral, light, strong

Quick curing (fast, one shot co-curing)

Easy lay-up, no potting

Good skin consolidation / tight skin / avoid re- work

Stable process with high yield, no core stabilization cycle

Precise core fit, no adjustments needed

Fewer parts, no secondary bonding

Outsourced shaping / no waste

Quality, ready-to-use parts / low inventory

No freeze damage or skin debonding

Excellent fatigue

Low finished part weight

Easy to repair

No water ingress

ROHACELL Triple F®

Requirements from OEMs:

“Competitive costs for composites”

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Overallcost

current

composite costs requested

costs

100 %

Production

process has

the biggest

potential to

decrease

costs!

0 %

Autoclave, Prepreg

Hand Lamination,

HP-RTM,

Wet-compression

Number of Parts

Slow

Fast

Production process

Reduce production costs Increase production volume

Choose the right core

ROHACELL Triple F®

Triple F technology

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New approach for production of cores

Standard production of ROHACELL® foam sheets

The newest product technology is

ROHACELL® Triple F core

Pellets Filling

the mold

Foaming Cooling

Demolding

Ready-to-use

cores

ROHACELL Triple F®

Design freedom

10 ROHACELL Triple F®

• 3D foaming of complex structures

• Direct foaming in a mould

• Large scale production of foam cores for mass industries

e.g. Automotive and Sports

• Virtually no scrap

Material advantages


• Different densities according to the part / process requirements

possible :70 – 200kg/m³)

• High temperature resistance: Tg ~200°C

High injection pressure and high temperature allow shorter curing

cycles (e.g. in RTM or Wet pressing)

Process benefits for customer


Direct integration in

• RTM, Autoclave, Compression molding (etc.)

• No outgassing

• High fault tolerance

• Tight tolerances are possible

ROHACELL Triple F® 13

Additional Advantage

ROHACELL® Triple F core allows functional integration

Direct insert integration


• Inserts can easily be integrated

• Direct integration in thefoaming process

• No gluing

• Tight tolerances (+/-0,1mm)

Functional integration


• Integration of hollow structures

• Integration of channels (e.g. for cables)

• Integration of stiffeners like rods or tubes

New Development: Functional Integration

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Full Panel with CF top layers

ROHACELL® Triple F

ROHACELL Triple F® 17

ROHACELL® Triple F offers our customers

Design Freedom

Material Advantages

Process Benefits

Functional Integration

LiteCon GmbH

Werner Stoeger

Director Sales & Marketing

Phone: +43 3852 36100

Fax: +43 3852 36100 9

[email protected]

www.litecon.at

Please feel free to contact us:

mailto:[email protected]

http://www.litecon.at/

Mechanical performance


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ROHACELL Triple F®

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ROHACELL Triple F®

fast furious foamed rohacell® triple f 3d foam cores

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