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We have pilot plants with most of the composite transformation processes, whereby we are able to obtain proofs of concept, demonstrators and prototypes of parts in different sizes and scales.
We can define the most suitable transformation process for each part depending on the design, type of material and production rates.
We are working on the monitoring and control of composite moulding processes through the incorporation of sensors, artificial vision, monitoring technologies, AI and digitalisation.
The following pilot plant technologies are available at GAIKER:
• Manual lamination
• SMC, BMC
• Prepregs
• RTM, RTM light, C-RTM
• Infusion
• Compression
• Vacuum pressing
• Filament bonding
• Pultrusion
• Lamination by double tape press
• Unidirectional thermoplastic tape production
• Microwave curing
• UV curing
• 3D mould printing
We analyse process conditions and prototyping for polyester, phenolic, furanic, epoxy, PU systems.
We obtain prototype batches of these materials based on a specific formulation.
We study the compression process of SMC, prepregs, and other materials, and the production of prototypes.
We manufacture prototypes of tanks and tubes in fibreglass and carbon fibre
We study the process of obtaining profiles with different materials, and the manufacture of prototypes
The aim of the European INFINITE project is to provide continuous information on the condition and status of aerostructures at any point in their life cycle using smart materials and wireless technologies.
Composites will be developed with integrated sensors as part of the initiative to monitor the characteristics of these materials from their manufacture to their final recycling, with the aim of extending their useful life and improving their quality
The COMVAC project is focused on improving the manufacturing processes of composite materials for the transport sector by developing an automated vacuum moulding cell for prepregs to manufacture lightweight structural components.
The aim of this project is to develop a new manufacturing cell based on advanced, intelligent organisational models to automate large composite manufacturing processes. GAIKER's research is focused on the control and automation of resin injection processes, developing preforms with constant section reinforcement and designing and developing demonstrators for the railway and shipbuilding sectors
The aim of this project is to achieve greater efficiency in the manufacture of composites, improve the performance of finished products and develop a system for predictive maintenance throughout the life cycle of the product and during the production process. In this project, GAIKER was responsible for obtaining data on mould filling and the kinetics of curing thermosetting resins in the RTM injection process, by adding sensors to the mould and including magnetic fibres in the composite.
The aim is to develop a highly productive RTM manufacturing process by applying the Industry 4.0 philosophy, so as to reduce costs (higher productivity and lower reject rate) and industrialise new composite products with high added value in the automotive sector. GAIKER’s research is aimed at adding more sensors to composite manufacturing methods, not only for control purposes during the production process, but also as a tool for predictive maintenance during the useful life of the composites.
Subsidised by the Basque Government
The project is aimed at developing a flexible manufacturing technology based on the use of thermoset prepegs for personalised short and long production runs which require high productivity. Process and product simulation and modelling tools are used in the manufacturing process, along with monitoring and communication tools between the stages involved in order to ensure overall quality.
The aim of the KAIROS project is to research into cutting-edge technologies in composite manufacturing, Industry 4.0 and Digital Twinning aimed at developing a solution for the efficient manufacture of large composite parts for the naval sector, with a high degree of automation, as well as quality and cost optimisation.
GAIKER’s research in this project focuses on different lines that cover the definition of the design of composite material parts, the control and automation of the manufacture of composite by infusion and the pre-forming of dry fibre reinforcements by means of vacuum and temperature compaction, and the development and characterisation of functional prototypes.
Thermoplastic composites are an excellent alternative to thermoset composites and sheet metal. However, implementing them in the market requires overcoming certain limitations associated with processing them. To this end, the ZE-KOMP project was set up to work on developing optimised, reliable manufacturing processes, improving the sustainability of these processes from an environmental and cost point of view, and on manufacturing rates.
Subsidised by the Basque Government
Sustainable Composites & Functional Polymers Market Manager
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