At JAKSCHE, digitalisation with smart management systems has well and truly arrived. Through this means, processes in construction, tool making, series production and quality assurance are networked and controlled efficiently. An additional recipe for success lies in the training and development of young specialists.
A wide variety of technologies for series plastic parts
JAKSCHE uses a wide variety of process methods and injection concepts for the manufacture of series-production plastic parts. With the profound technological expertise of our employees, we can offer series production for our customers as an integrated technological solution. JAKSCHE can flexibly cover a broad range: from a one-off, tailor-made product to several thousand units.
Technologically demanding plastic components in large sizes of up to 13 metres in length is what JAKSCHE does.
Hand lamination is the most traditional manufacturing practice for the layer-by-layer building of fibre composite components. Due to the minimal investment costs and maximum freedom in component forming, this method is suitable for smaller series production with components of almost any size and complexity. Typical components are boats, containers, covers and prototypes of all kinds.
With hand lamination, employees work from the outside inwards: after applying a release agent on the mould surface, a gelcoat covering layer is pasted or sprayed on. Once the gelcoat cover layer has gelled, the fabric layers – consisting of glass fibres, carbon fibres, aramid fibres and natural fibres – are put into shape wet in wet using hand-held rollers, grooved rollers or brushes. Even more special materials, such as sandwich panels, or a lightweight core made out of foam or honeycomb, can be inserted in a particular designated sequence. Only through the combination of fibres and plastic and the firm bonding of the plastic matrix to the fibres can highly resilient components be produced for lorries, caravans, earth-moving machinery and agricultural machinery.
The laminates cure unpressurised at room temperature. Certain resin systems require higher temperatures for optimum curing. The components are then additionally tempered either in the mould or after demoulding.
Once the components have fully cured, further processing occurs; e.g. trimming, grinding, gluing, etc.
Characteristics of the hand lamination process
- Low investment costs
- Very suitable for small to medium-scale series production of up to 1,000 units
- Containers, casings and prototypes of all kinds
- Components for lorries, caravans, earth-moving machines and agricultural machines
Vacuum infusion is a simple resin injection process for producing cost-effective, fibre-reinforced series-production plastic parts at low processing temperatures and reduced injection pressures. With this technology, large car body parts – such as bumpers, wheel arch panels, engine covers and decorative cladding – both for the exterior and interior can be manufactured efficiently without any problems.
The advantage over hand lamination is the high degree of reproducibility. With vacuum infusion, in addition to a single-part working mould, a vacuum film or vacuum covers produced by JAKSCHE itself, consisting of two-component elastomers, are used. The master model of the vacuum cover is derived from our very own constructed CAD model for the tool. On top of this we have flowing aids and sealing equipment, the equalisation of the transition points and the designation of provisions to ensure the vacuum cover keeps its position at the appropriate points.
Valves are located at various points. Suction is performed through some of them by means of vacuum, while resin is injected through others. The air between the film or the vacuum cover is sucked up and, through a second connection, the fluid resin is injected into the mould by means of the vacuum generated.
This entire process is performed in a highly controller manner. The actual lamination is pretty much automatic: when the tap for the resin flow is opened, the vacuum draws the resin into the fibres. Specialist knowledge and experience is necessary for this, too. Once this process is recorded, this will always guarantee identical components – which is of immense importance in series production.
Characteristics of the vacuum infusion process
- Moderate investment costs
- Very suitable for small to medium-scale series production of up to 3,000 units
- Components of less weight but of equal strength
- Size of the components > 2m / very large 13 metres
- Large, three-dimensional fibre-composite structures with complex shapes
- High-precision components with defined end wall thickness
- Broad product application for vehicle construction and the boating and leisure industries
Resin transfer moulding
The resin transfer moulding (RTM) process differs from the vacuum infusion process in the design of the forming tools. In the RTM process, the tool consists of an upper and lower mould. While the filling of the cavity in the vacuum infusion process is performed by applying a vacuum, with RTM the matrix material is injected into the cavity by means of positive pressure. In LRTM, a low-pressure injection is performed with additional vacuum support. The RTM technique is used in a wide variety of industrial sectors: the construction industry, vehicle construction, boat and ship building, sanitary engineering, system and machine building, electrical engineering and energy technology.
In the RTM process, various fibre materials, core materials (sandwich panels with honeycomb cores, polyurethane foam, balsa wood, and much more) and resin systems (such as polyester, vinyl ester, epoxy or phenol resins) are used. Due to the flexible combination options of different fibres, sandwich elements and free-flowing resins, many customer-specific requirements can be met with the RTM method.
After inserting the fibre reinforcement in the cavity of the tool, it is closed and the reaction mixture of resin, hardener and any catalysts is injected into the cavity under pressure. The reinforcing structure is impregnated with the mixture. The entire mould is then tempered.
After the component has been removed from the mould, the tool must be cleaned of existing resin residues at the sprue, riser and, where applicable, also at the edges prior to the next production cycle.
Characteristics of the LRTM process:
- Moderate investment costs
- Very suitable for medium to large-scale series production of up to 5,000 units
- Size of the components up to 5 m²
- Post-processing is reduced or rendered entirely redundant (near net shape manufacturing)
- Finished components have a high-grade, coatable surface
- High degree of process reliability and repeatability
- Components are high-strength
In thermoforming – also referred to as plastic deep drawing, and its simplified version is vacuum forming – thermoplastic plates are heated by means of a vacuum and pressed against the tool geometry. While the thermoplastic is cooling down, it retains the shape of the tool. The GEISS T 9 deployed with a mould area of 3,000 mm x 2,000 mm produces large-scale covers, from 2 mm up to 15 mm of thermoplastic
Deep-drawing specialist from Bosnia
A sophisticated production hall design leads to an efficient workflow for the thermoforming process.
The pre-dried thermoplastic plates are fixed in a clamping frame. The thermoplastic plates are then heated and pressed from underneath against the hot thermoplastic plate.
Feeding plates into the pre-heating section is possible by means of vacuum grippers. During this time, the moulding station next door produces the component just after the final heating phase. Prior to manual removal, there are just a few steps for punching or trimming, whereby the edge is removed in a few seconds. After the separation of the mould edge from the deep-drawn part, punching and CNC machining stations follow, before it ends up in final assembly, as per the logical sequence. Adhesive is the choice for surface adhesion or strict visual requirements. Fixing clamps and holders on the workbenches suggest that a lot of gluing goes on. If welding is not being performed, then gluing is.
Characteristics of the thermoforming process:
- Moderate to high investment costs
- Large-scale production of up to 15,000 units
- Demanding components for caravans and motorhomes
- Components for building systems and energy technology
The production of plastic parts is often not over after the respective manufacturing technology. Depending on component specifications, the plastic parts stay in specifically produced templates in a tempering furnace at up to 80 degrees for several hours subsequent to the series-production manufacturing process.
With the tempering process, plastic components can be subjected to a much quicker curing process, and the fibre-reinforced plastics obtain their optimum strength.
This thermal treatment is generally performed prior to demoulding the component. The optimum duration of the individual tempering phases, the temperatures and the temperature cycles depend on the material and its wall thicknesses. Through tempering, the resin molecules are quickly and fully interlaced, and the quicker volume shrinkage ensures the plastic has optimum product characteristics.
We have to remove volatile, low-molecular components from our products which could otherwise have an impact on the human body in interior or cabin components. Often, we achieve the desired mechanical properties even just through tempering. Meanwhile, new material types are on the market that contain almost no low-molecular components anymore. Due to the regulatory hurdles, customers are very reluctant to replace a tried-and-tested material for a product. Furthermore, because of the tempering shrinkage for existing products, new tools will almost certainly have to be built. In most cases, this is not financially appealing to customers. For new projects, getting to grips with the benefits of low-molecular material types is worthwhile.
After tempering, the next processing steps occur, such as robotic cutting, painting and the installation of built-in parts.
Automated robot milling cell
When it comes to plastic components within a size range of up to 13 metres in length and a weight of up to 5 tons, state-of-the-art technology is worthless without the right automation. A highlight at JAKSCHE is the predominantly autonomous robot milling cell as an automation solution for the milling of series plastic parts. Two other KUKA robots are used for the milling and trimming of smaller components simultaneously.
In order to be able to work more quickly and efficiently in series production, JAKSCHE has invested in two cooperating KUKA industrial robots for the automatic processing of milled parts. Consequently, JAKSCHE customers can be satisfied with their requirements regarding tolerance specifications and data clarity.
The autonomous standard robot cell consists of floor-integrated KL400 1CA rail tracks on which two KR100 robots and two vertical KP 1 V positioners from KUKA are installed with a payload of up to 500 kg. At this cell, various plastic components in their cutting templates can be docked to the industrial robot from two sides.
Simple separating cuts to complex 3D processing can be performed effortlessly in this way in short cycle times. To make optimum use of machine capacity, the operating times and reach capabilities of the individual robots are verified early on in the planning phase through simulations and coordinated. The SprutCAM software enables simulation and offline programming.
- Six controllable axes
- Maximum robot reach 3,501 mm
- Effective travel path 10,900 mm
- Repetition accuracy of the position ISO9283 +/- 0.05 mm
- Maximum speed 1.8 m/s
- Automatic tool changer
- Automatic calibration system
- KUKA TouchSense software for the measurement of workpiece probe systems
- Spindle power ISO30 with 24,000 rpm
For the manufacture of complete assemblies and product modules, we have been using adhesion as a bonding technique for a few years. JAKSCHE assumes full system responsibility for complex assembly tasks. By using adhesive joining processes, we are able to produce machine components, force applicators, components with flanges and sub-assemblies made of a wide variety of materials (titanium, aluminium, steel, etc.).
In addition to structural applications, adhesives can also be used as sealing and insulation materials.
A composite material joined with adhesive offers numerous advantages: even stress distribution, leak-tightness, thermal insulation, electrical conductivity, the bridging of tolerances, the prevention of contact erosion, and much more.
We offer the conditions in terms of premises and personnel to perform adhesive bonding to meet the strictest of quality and safety requirements and will support you with new developments, constructions or optimisations of components in relation to adhesive bonding. The quality of our adhesive bonds can be demonstrably ensured using internal testing equipment and with the cooperation of external testing laboratories.
Surfaces are amongst the most highly stressed parts of components in pretty much all industries. Together with special primers, industrial paintwork offers a high degree of corrosion protection while simultaneously refining the components. The manufacture of effect finishes with matt, glossy or structured surfaces can be achieved effortlessly in JAKSCHE's clean room paintshop.
With our specialist team, we provide industrial paintwork in fine structures or high-gloss surfaces in a state-of-the-art-equipped industrial painting chamber. The modern clean room paint shop guarantees the highest quality and accuracy. Even larger components can be painted easily in our 7,000 mm x 4,080 mm x 2,800 mm-large paint booth. Our processes and methods certified to ISO and customer-specific standards ensure compliance with the most stringent of requirements. Thanks to the painting processes we use, we guarantee our customers optimum opacity, enormous colour-tone brilliance, excellent coat distribution and high UV resistance.
Fields of application:
- The painting of metals and plastics for series production and spare part products
- Industrial painting in special colours
- Matt, glossy or structured surface effects
- Use of environmentally compatible water-based paints