Pultrusion - Creating profiles in lightweight design

Pulling together - not just an approach, it's our passion

Continuous fibre-reinforced plastic profiles can be produced efficiently and economically using the pultrusion process, also known as the strand drawing process. Starting with dry fibres or textile semi-finished products, these are impregnated with a matrix system in the next process step, which then cures in a heated mould to form a solid profile. Thanks to their customised reinforcement structure, they can withstand high loads. At the same time, they are very lightweight and therefore have enormous potential for lightweight construction. In addition to the production of straight profiles, the Fraunhofer IWU can also manufacture constantly curved structures. Various cross-sectional geometries can be realised, from solid profiles to complex multi-chamber hollow structures. Due to the continuous process sequence and the high pull-off speeds of up to 2,500 millimetres per minute, the process is very economical and predestined for medium and large-scale production.

Service portfolio

Over 10 years of experience and a large network along the entire process chain speak for convincing services from our point of view. With our equipment ranging from our series-capable pultrusion system to a variety of system add-ons (e.g. injection systems, fibre tempering, etc.) and analysis technology, we are ready to meet your requirements. Let us achieve your goals together with highly qualified development experts from the idea to realisation and testing. With our range of services, we already cover everything from classic pultrusion from the resin bath to the production of sustainable thermoplastic profiles. Contact us and let us develop your customized solution.

  • Profile design and layout
  • Structural engineering and component simulation
  • Simulation of the impregnation & curing process and the resulting distortion
  • Tool design & construction
  • Development & layout of injection tools and impregnation strategies
  • Process development & profile realisation (on our own series production system)
  • Component sampling
  • Quality monitoring incl. inspection and testing
  • Training and qualification

Equipment

Process technology

  • Pultrusion line
  • max. pull-off force 80 kN
  • max. pull-off speed 2.5 m/min
  • max. profile cross-section 300 x 150 mm²
  • 15 individual heating zones
  • open impregnation or direct injection
  • integrated temperature and pressure measurement
  • option for radius pultrusion
  • pool on various trial moulds

Impregnation technology

  • Mixing and dosing systems for polyurethanes, epoxies (amine-based), caprolactam
  • Tube pump and pressure pot
  • Extruder
  • Various resin baths

Fiber preparation

  • Creel for external take-off (300 winding positions)
  • Creel for internal take-off (500 winding positions)
  • Racks for semi-finished products (48 winding positions, multiple loading)
  • Reel cutter for textile finishing
  • Fiber preheating line
  • Winding machine

Analysis technology (selection)

  • Rheometer & DMA (MCR 702 MultiDrive from AntonPaar)
  • DSC incl. UV module (300 Caliris® Supreme from Netzsch)
  • DEA (288 Ionic from Netzsch)
  • Geltimer® (PST-1 from Gel Instrumente)
  • Microscope (VHX 5000 from Keyence)
  • Temperature measurement
  • Pressure measurement
  • Moisture measurement
  • Analyzing scales