Manufacturing 2018-03-07T13:37:42+00:00

Plastic pressing plant

Our company produces polyurethane products in round-the-clock operation on three pressing units using injection technologies. We produce parts that weigh from as little as a few grams (caps, fog lights…) up to several kilograms (bumpers, disguises…). We use RRIM (Reinforced Reaction Injection Moulding) technology in our production. The basis of this technology consists of three elements: polyol, isocyanate and filler (small glass or mineral fibres), which are mixed in precise ratios that significantly impact the properties of the part produced according to our clients’ specifications. Adding mineral fibres into the mixture significantly improves strength and rigidity, while relative prolongation is decreased or thermal resistance is increased. The use of concrete filler depends on the product requirements specified by the client. At present, the RRIM technology is mainly used in the automotive industry (production of diffusers, disguises, bumpers, spoilers, fenders etc.), particularly for strengthening parts, rigidity, thermal resistance and safety. Products produced using this technology can also be found in other industries.

Our clients include

Technology

PRESS 1 – EP Pressentechnik

closing force table size closing stroke of the press maximum closing speed maximum opening speed
300 tons 3000 x 1500 mm 2200 mm 400 mm/s 250 mm/s

PRESS 2 INO

closing force table size closing stroke of the press maximum closing speed maximum opening speed
250 tun 3000 x 1500 mm 1300 mm 190 mm/s 190 mm/s

PRESS 3

closing force table size closing stroke of the press maximum closing speed maximum opening speed
600 tun 3500 x 2000 mm 2300 mm 325 mm/s 220 mm/s

Moulding technology

HS-RIM rapid moulding
Krauss Maffei 1 – Comet 240/240 – 20/20
Krauss Maffei 2 – Comet 200/200 – 20/20
Slow moulding Cannon A CMPT 40 FC

Paint shop

We use various manual paint booths and have an automatic painting line with three robots.Our painters are experienced in painting the most widely differing products in many combinations and forms:

  • plastics (polypropylene, polyurethane …), particularly exterior and interior components for the automotive industry
  • metals – full bodies or parts
  • composites (carbons, laminates)
  • Uriol artificial wood
  • clay models of cars and components

Manual applications of solvents and water-based paints

This modification to surfaces of various materials and shapes, as previously mentioned, is applied in paint booths equipped with cutting-edge technology serviced by a professional team of employees. Manual painting takes place in six separate paint booths where we apply water-based or conventional paint in single or multi-layer coats. The unquestionable advantage of hand-painting is flexibility, the ability to paint different-sized and shaped complex parts, in small and large batches. All production processes are subject to a ISO 9001:2001 control and quality management system that is regularly and efficiently audited. The greatest reward for us, however, is customer satisfaction and repeat orders.

Technology

3 x Termomeccanica Powertherm booths
3 x Termomeccanica GL2 MEGA TOP booths

Automated painting with water-based paints (AFOTEK)

Capacity

Number of shifts per day: 3
Number of working hours per year: 5,500

Technological data

Robotic application of liquid paints with VOC content < 7 % using three six-axis FANUC robots (1x flaming, 2x paint application). Representative of the coating system: two-component, water-based polyurethane base coating designed for coating plastics and metals, for example: Audigrau, Steingrau, Reflexsilber …

Handling and transport of parts

Transport of parts between sites is carried out by the floor transport system.
Maximum suspended load: up to 30 kg/Skid.
Plate hangers: approximately 1,440 mm.
Conveyor speed – continuously adjustable from 0.8 to 2.5 m/min.
Default speed of the conveyor used: 1.5 m/min.

Line throughput

Depending on the task, parts measuring circa 1,200 x 1,100 x 400 mm (width x height x depth) can be varnished.

Composites

For many years, our company has been producing quality custom-made products from composite materials, among others, for the automotive industry. The most commonly used types of materials in our production are carbon fibres (carbon fibre composite and resin to achieve maximum strength and lightness) and fibreglass (composite made from glass fibres and mostly polyester resin). Our portfolio also includes carbon composites and carbon kevlar.
To produce carbon fibre parts we use so-called pre-pregs (woven carbon fibre, glass, or otherwise combined mat together with pre-impregnated, partially wilted resin). Prepared pre-preg workpieces are manually placed in the mould, in layers up to the desired thickness of the piece, before being subjected to evacuation. Individual components produced using this technology can then be sprayed in any colour scheme while retaining the lowest possible weight. We can design and then implement the preparation of models, parts and moulds for this technology.

This procedure enables us to achieve maximum adherence, with the ability to shape even more complex forms. The prepared parts are subsequently hardened in an autoclave. We strive to provide the most precise overlay of pre-preg fibres in order to achieve a perfect appearance and robust mechanical properties for all parts.
We use fibreglass parts most frequently when building prototype parts or cars, where the emphasis is on the speed of preparation and a relatively low price. We produce carbon-fibre parts for both the automotive and motorcycle industries as well as for the tuning, motorsport, aeronautical and furniture industries.

Technology

Autoclave 1

Manufacturer Magnabosco
Volume 11,000 l
Working temperature up to 180°C
Working pressure up to 6 bar

Autoclave 2

Manufacturer Maroso
Volume 6,200 l
Working temperature up to 200°C
Working pressure up to 10 bar

Autoclave 3

Manufacturer Scholz
Volume 24,000 l
Working temperature up to 200°C
Working pressure up to 10 bar

Car assembly

We offer assembling of units in our assembly areas – mounting of styling accessories directly on cars or sub-assembly for automotive manufacturers and individual end users. Furthermore, we also provide assembly of accessories for show cars and presentational cars, both in our workshops, and even at customer’s premises, thanks to external group of mechanics equipped with mobile workshop.

Technology

9x two-post lift
2x mobile lift
1x platform lift
1x light tunnel