2. fiberforge relay station brochure
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8/10/2019 2. Fiberforge RELAY Station Brochure
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Lightweighting Your World.
Rapid
Efficient
Layup
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8/10/2019 2. Fiberforge RELAY Station Brochure
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Fiber reinforced thermoplastics are
the future of structural composites.
Thermoplastics offer excellent
toughness, stiffness, impact
attenuation, chemical resistance
and flammability performance.
High material and processing costshave prohibited the adoption of
thermoplastic composites for volume
applications. Enter Fiberforge. With
Fiberforge, advanced composites in
high volume production applications
are an economic reality.
Fiberforges RELAY Station is an
automated thermoplastic tape
layup system. RELAY stands for
rapid, efficient layup, and both
the equipment and the process are
protected by patents.
Fiberforge designs and produces
its RELAY Station equipment and
sells to manufacturers, worldwide to
make strong, lightweight and cost-
effective parts.
Fiberforge partners with other
equipment suppliers and system
integrators to offer complete
manufacturing solutions.
Fiberforge RELAYStation
Breakthrough technology for the rapid
production of advanced composite parts
Rapid lay-up of tailored blank
by RELAY Station: minute one
Consolidate blank: minute two
Thermoform blank: minute three
Fiberforge technology:
Extremely high
throughput
processes over 200 lbs.
(90kg) of material per hour
Automated
Accurate, repeatable
and reliable
Intuitive, easy-to-use
interface
Unsurpassed design and
engineering support
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Fiberforges patented RELAY Station is a state-of-the-art
tool for the rapid, high volume production of fiber-reinforced
thermoplastic composite structures.
Process Summary
The RELAY Station includes a rapid
tape dispensing system, which feeds
composite tape through a track
positioned above a two-axis motiontable. Based on the specifications
of the part being produced, tape
lengths are fed into the track, cut,
and placed on the table. As the tape
is placed, a series of ultrasonic weld
tips descend and rapidly tack the
tape to the ply beneath it.
Following welding, the table
indexes to a new position to lay the
next course. This process repeats
until a multi-ply tailored blank is
constructed. Following lay up, the
blank is removed, then consolidated
and thermoformed into a 3D part.
Fiberforges proprietary software,
TailorGen, generates the tailored
blank design from a 2D model and
feeds the design to the RELAY Station
for production.
RELAY Station
Operating System Specs PC-Based Operating System 9 Servo Axes
Windows-based operatingplatform
Touch screen, full manualand auto control
Advanced error indicatorsand data logging
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RELAY 1000 Series 2000 Series
Max. Blank Size 1m (40") x 1m (40") 2m (79") x 2m (79")
Footprint 5.7m (18.7') x 5.5m (18') 7m (23') x 9.6m (31.5')
Maximum Throughput* 230 lb./hr. 368 lb./hr.
Tape Width Range 50 mm (2") - 150 mm (6") 50 mm (2") - 150 mm (6")
Tack System 10 weld heads 18 weld heads(with power supply and sequencer)
Vacuum Table 2 zones 8 zones
*Actual throughput may vary based on tape width, part design, material type and machine options.
Fiberforge RELAYStation
RELAY Station Specifications
System Specifications and Upgrade Options
FiberforgeCorporation
1420 Devereux Road
Glenwood Springs, Colorado
81601 USA
phone +1.877.945.9377 | +1.970.945.9377
FiberforgeGmbH
Mattweg 3, CH-6340 Baar, Switzerland
phone +41 (0) 44.58.66.77
[email protected] Fiberforges technology is protected byU.S. patents 6 ,607,626; 6,939,423; 7,235,149; 8,007,894;8,048,253 and patents pending. 2012, Fiberfo rge Corporati on. FFRS1212V6
fiberforge.com
Standard Option
Resolution C = 0.01
Y = 0.025 mm (0.001")
U = 0.1 mm (0.004")
Repeatability C = 0.05
Y = 0.2 mm (0.008")
U = 2.0 mm (0.080")
Minimum Course Length 86 mm (3.4")
Tape Width Tolerance 0.4 mm (0.016")
Tape Thickness Range 0.1 mm (0.004") - 0.4 mm (0.016")
Graphic User Interface Windows-based touch screen
Part Logging Textfile SQL database connectivit y
Warranty 1 year 3 or 5 years
Weld Method Simultaneous Simultaneous
Creel System Double creel
Tape Loading Manual Automatic
Part Removal Manual Automatic
Carriage Tray Auto adjust