FAST FURIOUS FOAMED ROHACELL Triple F 3D Foam Cores. Mr. Werner Stoeger

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1 FAST FURIOUS FOAMED ROHACELL Triple F 3D Foam Cores Mr. Werner Stoeger

2 FAST FURIOUS FOAMED 3D foam cores for high volume production of composite components in superior product quality

3 An attractive company 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 LiteCon GmbH 3

4 Evonik Industries AG 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 4

5 SECAR 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

6 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.

7 Why using ROHACELL? Processing 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 Logistics Fewer parts, no secondary bonding Outsourced shaping / no waste Quality, ready-to-use parts / low inventory In Service Performance No freeze damage or skin debonding Excellent fatigue Low finished part weight Easy to repair No water ingress 7

8 Requirements from OEMs: Competitive costs for composites Overallcost Production process 100 % Production process has the biggest potential to decrease costs! Fast Autoclave, Prepreg Hand Lamination, HP-RTM, Wet-compression 0 % Slow current composite costs requested costs Number of Parts Reduce production costs Increase production volume Choose the right core 8

9 Triple F technology Standard production of ROHACELL foam sheets The newest product technology is ROHACELL Triple F core New approach for production of cores Pellets Filling the mold Foaming Cooling Demolding Ready-to-use cores 9

10 Design freedom 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 10

11 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) 11

12 Process benefits for customer Direct integration in RTM, Autoclave, Compression molding (etc.) No outgassing High fault tolerance Tight tolerances are possible 12

13 Additional Advantage ROHACELL Triple F core allows functional integration ROHACELL Triple F 13

14 Direct insert integration Inserts can easily be integrated Direct integration in thefoaming process No gluing Tight tolerances (+/-0,1mm) 14

15 Functional integration Integration of hollow structures Integration of channels (e.g. for cables) Integration of stiffeners like rods or tubes 15

16 New Development: Functional Integration Full Panel with CF top layers ROHACELL Triple F 16

17 ROHACELL Triple F offers our customers Design Freedom Material Advantages Process Benefits Functional Integration ROHACELL Triple F 17

18 Please feel free to contact us: LiteCon GmbH Werner Stoeger Director Sales & Marketing Phone: Fax: w.stoeger@litecon.at

19 Mechanical performance 19

20 Mechanical performance 20

21 Mechanical performance 21