EVERYONE TALKS ABOUT FOOTPRINT, WE MOVE FORWARD!

WIR GARANTIEREN EFFIZIENZ DURCH IMMENSE MATERIALEINSPARUNGEN HÖHERE FESTIGKEITEN EINEN SICHEREN PROZESS TOP PERFORMANCE ERCHEBLICHE KOSTENVORTEILE NACHHALTIGKEIT

EFFICIENT LIGHTWEIGHT SOLUTIONS FOR THE MARINE SECTOR

Watercrafts are only as good as the materials used. Thanks to our profound know-how in the development and production of fibre composite components and structurally reinforced foam cores, ship and boat builders worldwide have been relying on our products and services for years. With our forward-looking solutions, we live up to our high standards of sustainability and environmental protection.


Benefit from our innovative lightweight solutions for a sustainable future.

3D|CORE™ COMPONENTS

  • BOOMS, SPARS & MAST
  • INTERIOR
  • PREFABRICATED STRUCTURAL REINFORCEMENT
  • HIGH PERFORMANCE – COMPOSITE KEEL
  • HULL
  • DECK

DECK

 

  • Fast, easy IT-assisted placement of foam core and fibre cuttings into complex shapes – whether convex or concave, with tight radii and large surfaces
  • The flexibility of 3D|CORE™ allows large cuts to fit the contour of the mould effortlessly
  • No risk of delamination due to the connection of the face sheets with the 3D|CORE™ structure
  • Excellent material properties – ultra light & rigid
  • Optimization of the material thicknesses and weights of the fibre face sheets

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HULL

 

  • No intermediate vacuum is needed to fixate the materials in the mould
  • Excellent material properties – ultra light & rigid
  • No water absorption
  • High collision damage tolerance as the 3D|CORE™ structure holds the laminate together and prevents sudden death
  • Safe & simple production process
  • Integration of functional groups

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STRUCTURAL REINFORCEMENT

 

  • Prefabricated elements made of sandwich construction panels
  • Simple plug-in system as a kit
  • No moulding costs
  • Maximum strength and stability
  • High weight saving
  • High dimensional stability

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BOOMS, SPARS & MAST

 

  • Fast & safe manufacturing process with 3D|CORE™ TAPES for winding machines
  • Significant weight saving
  • Increased strength
  • Reduction in the use of expensive materials such as carbon, basalt, etc.
  • No mould construction costs
  • Varying cross-sections and shapes possible

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HIGH PERFORMANCE – COMPOSITE KEEL

 

  • Maximum strength
  • High damage tolerance
  • Maximum safety against grounding
  • No water absorption
  • Material saving potential
  • High fatigue strength
  • Low weight at full righting moment
  • Improved performance

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INTERIOR

 

  • Floors (IMO Part 5): high stiffness & strength
  • Partition walls: good insulation & acoustic properties
  • Ceiling design (IMO Part 5): high dimensional stability
  • Fixtures: maximum design freedom
  • Wood coating/veneering according to IMO 2010 FTP Code Part 5 possible
  • Low weight

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3D|CORE™ TECHNOLOGY

3D|CORE™ is a patented honeycomb structure that is inserted into a closed-cell PET and XPS foam core. The honeycombs, which are connected to each other via small bridges, run through the entire foam core and enable a high flexibility of the core. Between the individual honeycomb foam bodies are cavities that are filled with a matrix of synthetic resin and support the filling process as an integrated flow aid. Once the matrix has cured, the fibre-foam core-system retains its shape and develops excellent technical properties. The cover layers on both sides of the foam core are connected to each other via the honeycomb structure. This prevents, in contrast to other sandwich structures, that the cover layers from detach from the core (delamination) and furthermore prevents the component from failing completely and abruptly.

RESIN RECYCLED 3D CORE™PET GR FOAM CORE

YOUR BENEFITS

Available with different features:

  • Recycled from post-consumer plastic (3D|CORE™ PET
    GR)
  • Fire retardant with excellent FST properties (3D|CORE™
    PET FR)

In different densities

Maximum freedom of design:

  • Flexibility
  • 3D formability
  • 3D|CORE™ PET follows complex shapes and contours

Homogeneously filled component:

  • Significant savings in consumables (no flow aid).
  • Process reliability
  • Easy processing in vacuum infusion, hand laminate and RTM
  • No intermediate vacuum

The resin bridges of the 3D|CORE™ structure hold the laminate together:

  • High damage tolerance
  • Optimal force distribution
  • Delamination almost impossible
  • In-plane compression load permissible
  • Long-term resistance

Excellent mechanical properties:

  • Improved shear & compression properties
  • High strength & stiffness
  • Excellent fatigue strength
  • Best performance

Sustainability:

  • Extremely low weight
  • CO2 & fuel savings
  • Recycled & recyclable material
  • High durability
  • Lower energy consumption in the manufacturing process
  • Less use of fibres and resins
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3D|CORE™ : BECAUSE EVERY STEP COUNTS!

Core materials: recycled, fire resistant, flexible & ultra-light with excellent strengths

Cut-to-size foam cores
and fibres

Economic & fast manufacturing process

Lighter & more durable ships

Reduced fuel consumption &CO2 emissions, better performance

Significant cost & competitive advantage

Alles in allem sorgen 3D|CORE™ Produkte für sicherere und schnellere Herstellungsprozesse von Komponenten und helfen darüber hinaus dabei, signifikant an Gewicht einzusparen. Dies führt wiederum zu einer immensen Verbesserung der Energiebilanz: Sie sparen Kraftstoff und helfen, den CO2 Ausstoß zu reduzieren. 3D|CORE™ ist der ideale Ersatz für metallische Werkstoffe, Balsaholzelemente und andere Standard-Schaumkerne.

3D|CORE™ MARINE ASSEMBLY KITS

With our  3D|CORE™ MARINE ASSEMBLY KITS you have the possibility to produce project-specific prototypes and series components quickly and easily. We are happy to support you with the necessary calculations, with the design of simple and complex components and with checking the technical feasibility. Additional advantage: the accelerated production process and the low storage and freight costs mean immense cost savings for you.

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THE PROCESS

Step 1:
Your 3D drawing

Step 2:
Generation of the 2D cut file

Step 3:
Production of the cuts

Step 4:
Inserting the 3D|CORE™ ASSEMBLY KIT into the mould

Our 3D|CORE™ MARINE ASSEMBLY KITS are not “off the peg”!

Our knowledge is based on our many years of experience and expertise in the the production of composite components for a wide range of applications.

  • 3D drawing incl. desired thickness and core properties
  • Checking of the drawing
  • Optimizations, if necessary

Determination of:

  • Number of cuts and components
  • Costs
  • Final weight
  • Delivery rhythm, quantity and packaging
  • Duration of the production process
  • Flattening process (from 3D to 2D)
  • Calculations
  • Checking the geometry of the cuts
  • Optimization for effective material use (nesting)
  • Generation of cutting files
  • Generation of a numbered insertion plan for easy application
  • Production of the required 3D|CORE™ material
  • Production of a 3D|CORE™ MARINE ASSEMBLY KIT prototype to minimize corrections to subsequent kits

After approval of the prototype and any corrections:

  • Production of the required 3D|CORE™ material
  • Production of the 3D|CORE™ MARINE ASSEMBLY KITS, consisting of3D|CORE™ foam core and textiles, in series production
  • Optimized packaging for particularly sustainable and safe transport

YOUR BENEFITS

Fix-in-place
technology:

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- Easy insertion
- Labelled cuts
- Insertion plan included
- High time saving
- Dimensional accuracy

All available from one source:

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- Cut foam core & cut fibres
- High time savings from the idea to the finished component
- Competent partnership instead of classic supplier relationship

Maximum
flexibility:

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- Fewer cuts
- No intermediate vacuum
- No gluing in
- Optimized chamfers and radii

Cost savings:

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- Low storage costs
- Lower labour costs
- Savings on auxiliary materials
- Lower freight costs
- Savings in energy costs

Sustainability:

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- Optimum use of materials
- Reduced waste
- Significant energy savings during production
- Improved CO2 balance

AREAS OF APPLICATION

SERVICES

The challenge: reduce the volume weight of watercrafts, but at the same time increase performance, range and productivity while still achieving savings in raw materials, costs and energy. We say: challenge accepted!

Our experienced engineering team supports you in finding the perfect composite solution for your project – from drawing to production. Together we will develop your ideas further and take on new challenges in order to develop the optimal lightweight solution for you. We support you in the design and construction, in the material selection, in the verification through material testing, in the optimization of the fibre composite components as well as in the production. In this way, we enable you to manufacture high-quality components in the shortest possible time.

Konstruktion

Our engineering team supports you from the very beginning in the implementation of your idea: throughout the entire production chain ...
all the way to the completion of your composite component. In order to allow an optimal design of your components, we analyze your planned lay-up, the product design as well as your requirements and wishes. Our specially developed 3D|Calculator calculates the technical properties of the composite component and simulates load cases to improve future performance. To validate our calculations, we produce prototypes which are then subjected to extensive testing in our test laboratory.

SANDWICH OPTIMIZATION

By comparing possible lay-up combinations (topology) with regard to their technical properties, we optimize...
your existing laminate plan and thus find the balance between weight and performance for you. To do this, we have access to an extensive database that we have built up with empirically determined characteristic values of a wide range of composite materials from our own materials research. Our development engineers are always actively involved in new material decisions. In order to always be able to make the best decisions for our customers when selecting materials and raw materials, we work exclusively with globally recognized manufacturers.

SUSTAINABILITY CONCEPT

Sustainability is a global priority. For all industries, it is necessary to drastically reduce CO2 pollution. Our solution: minimizing...
weight and maximizing component quality with the help of our 3D|CORE™ technology. We pay particular attention to reducing material and energy consumption in production and to using sustainable composite materials. For this reason, we rely on recycled and recyclable core material with excellent mechanical properties. Our 3D|CORE™ PET GR consists of 100% post-consumer recyclate obtained from plastic bottles. In addition, we fundamentally refrain from using substances that endanger people and the environment.

EFFICIENCY CALCULATION

Efficiency is important to us in every respect! Based on our many years of know-how, the data from our composite database and...
of course based on your wishes, we compare your existing lay-up, the process as well as the cycle times. In this way, we find out where optimizations, savings or improvements are possible. All these factors serve as a basis for your decision and as an indication for your calculations. The savings have a particular effect on the final component weight, the materials used (less resin, fibres and auxiliary materials) and on the process, material and labour costs.

PRE - SERIES PRODUCTION

In order to make first product samples cost-effective and quickly accessible in the development phase, we also design and ...
manufacture prototypes, machines, moulds and mould tools for you, in addition to our 3D|CORE™ ASSEMBLY KITS. With the help of our rapid prototyping, constructive optimizations can be detected quickly and then implemented cost-effectively. We also support you in integrating our lightweight construction solutions into your production. We also offer trainings so that you can implement your projects faster and more economically right from the start.

PRODUCTION

The use of lightweight components is essential to reduce fuel and energy consumption, improve the CO2 balance of a component...
and to increase the maximum load capacity. Decisive for this: the choice of the right manufacturing process! We will be happy to support you in selecting the right process for manufacturing your components. Our machinery, which is equipped with cutters and milling machines, various saws, welding machines, a labelling device, testing machines as well as an adhesive station, is at your disposal. To round off our wide range of solutions, we are happy to manufacture your lightweight components in small batches as well as individual pieces in our factory. For the production of large series, we bring our qualified partners on board!

CONTACT