Composite sheets: Advanced Technologies for Tailored Solutions

Composite sheets, also known as fiber-reinforced sheets, consist of multiple layers of different materials combined through specialized manufacturing processes. These sheets offer exceptional properties such as high strength at low weight, corrosion resistance, and excellent thermal and electrical insulation. They are widely used in industries such as automotive, construction, electronics, and aerospace.

Structure and Materials

A composite sheet typically consists of a matrix and reinforcing fibers. The matrix can be made from plastics like epoxy resins or other polymers, while the reinforcing fibers may be composed of glass, carbon, graphite, or aramid. This combination creates materials with superior mechanical properties, such as high tensile and flexural strength. Some applications require high heat resistance or specialized electrical insulation, where the selection of appropriate fibers and resins determines the specific properties of the composite sheets.

Advantages of Composite sheets

Composite sheets offer a range of benefits, making them attractive across various industries:

• Lightweight Construction: They provide high strength at low weight, which is particularly valuable in aerospace and automotive applications.
• Flexural Strength: Composite sheets exhibit excellent flexural strength, allowing them to withstand high loads without failure. Their high stiffness prevents significant deformation under load, making them ideal for structural applications where stability and dimensional accuracy under stress are essential.
• Corrosion Resistance: Composite sheets are resistant to environmental factors, making them ideal for use in harsh environments, such as in the offshore industry.
• Thermal and Electrical Insulation: Due to their structure, many composite sheets serve as excellent insulators, making them indispensable in electronics and power engineering.
• Workability: Composite sheets are easily processed and can be sawn, drilled, and milled with standard tools. Modern methods like waterjet cutting or CNC milling allow precise processing without delamination or cracking.
• Design Flexibility: Thanks to their adaptable manufacturing process, composite sheets can be molded into various shapes, making them ideal for customized solutions.

Manufacturing Processes for Composite sheets

The production of composite sheets involves various specialized processes selected based on the desired material properties, shape, and application. One of the most common methods is Resin Transfer Molding (RTM), where reinforcing fibers are placed in a closed mold, and liquid resin is injected under pressure. This technique allows precise control of resin volume and high surface quality for the finished panel, enabling complex shapes and dense structures.

Another method is pressing, where pre-impregnated fibers or fabrics (prepregs) are cured under pressure and heat in a mold. This method is ideal for applications requiring high strength and stiffness, as it enables uniform material distribution. Controlled resin content provides optimal mechanical properties and minimizes unwanted voids or air pockets.

Hand Laminating is a manual process primarily used for prototypes or small series. In this method, fibers or fabrics are layered and impregnated with resin by hand, then shaped into the desired form. Although labor-intensive, it offers flexibility in material choice and allows the production of parts with highly complex geometries.

These processes each offer unique advantages, and selecting the right manufacturing method depends on application requirements. While RTM is suitable for large, precise components, hand laminating is preferred when flexibility and customization are prioritized.

Applications of Composite sheets

Composite sheets are used across a range of structural and high-performance applications in industry. In aerospace, they are used in floor and fuselage structures, while in automotive, they contribute to the production of lightweight and robust body parts. In construction, composite sheets are often used in facades and insulating elements, where they leverage their insulating properties. In electronics and medical technology, they are essential as substrate material for circuit boards and prosthetics.

Conclusion

Composite sheets offer numerous benefits, making them indispensable for modern applications. With their outstanding combination of strength, lightweight, and adaptability, they help optimize products across various industries. Von Roll provides customized solutions that meet the highest standards of quality and performance.

Selection of Our Composite sheets

• Dimensions (Standard): 1170 x 1070 mm; 2070 x 1070 mm
• Special Dimension: 4300 x 1300 mm