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Digital Production Line at Voith Composites

Voith Composites

More than lightweight – Realize your vision in carbon fiber construction.

The unique combination of engineering competence and production know-how, as well as the outstanding characteristics of fiber composites, creates maximum value for you.

Talk to us! Find more details in our brochure

Core competencies

    Tailored stack made by Voith Composites
    Net-shape stacks and preforms
    Tailored semi-finished products

    We design and produce dry and pre-impregnated customized stacks based on your requirements. With our internally developed direct fiber placement and preforming technologies, we achieve near-net-shape fiber layup with local reinforcements as well as reduce scrap to a minimum or eliminate it completely. After fiber placement, forming of the stacks can be realized by stamp forming or double-diaphragm process.

     

     

    More details in our Onepager
    Filament winding by Voith Composites
    High precision rolls and shafts
    Filament winding products

    Composite rolls and shafts are manufactured with a high-precision filament winding process. The fiber is pulled from the coil, led through a resin bath and wound onto the mandrel. We develop rolls with lengths of up to 13 m, diameters up to 1.2 m and wall thicknesses of up to 70 mm. We support you with adhesive bonding, bold construction and customer-specified force introduction solutions for high loads and torques.

     

     

     

    Find out more in our onepager
    From Prototype to digital production line
    One-Stop-Shop manufacturer

    Because of our unique combination of engineering and production knowhow we provide strong support at every stage of the development process. Starting from the first idea, first prototype and small series to sophisticated large scale production. Voith Composites not only develops components and processes but also builds the necessary machines and automation in-house. Our specially developed systems take industrialized carbon fiber production to a whole new level.

    Our Smart Factory wins the JEC Innovation Award 2018

    What we do

      Tailored, semi-finished product Voith Composites

      Tailored stack
       

      Semi-finished, tailored stacks

      We produce tailor made netshape stacks and preforms for your application.

      We develop and produce dry and preimpregnated stacks depending on your requirements. Based on our internally developed direct fiber placement and preforming technologies, we achieve near-net-shape fiber layup and reduce scrap to a minimum or eliminate it completely. After fiber placement, forming of the stacks can be realized by stamp forming or double-diaphragm process. We are able to handle differentmatrix systems.

      Maximum cost efficiency and personalization meets carbon fiber

        The unique characteristics of carbon fiber can now be used on a whole new level: With a  fully automated, cost-efficient production facility and high-end processing technologies, Voith enhances development and production of customized carbon and glass fiber as well as hybrid solutions - usable for numerous industries and application areas. The machines we use have been developed and manufactured by ourselves. This is what makes us stand out in the market and why we are the perfect partner for your composites project.

        Our product and service portfolio covers

        • First concepts
        • Design of component prototypes
        • Construction of components prototypes
        • Production of small batches
        • Series production in industrialized manufacturing

        Core markets

          Find out about our current application areas and concrete projects that have been successfully realized: 

          Automotive

          Structural component
          Audi A8 CFRP rear wall

          The rear wall is customized for the Audi A8 and displays the largest component of the occupant call. With its optimized fiber layup with 6 to 19 carbon fiber layers, it significantly contributes to the torsional rigidity of the vehicle. The rear wall is manufactured in Voith Composites' in-house developed production line and is designed to manufacture approximately 65,000 components each year. At JEC World 2018, we received the JEC Innovation Award 2018 for this digital production line.

          digital production line wins JEC Award 2018
          for inline e-coating and painting
          Class A surface for inline e-coating

          We manufacture CFRP parts with a Class A surface suitable for inline e-coating and painting processes. The blanks are produced with our self-developed preform technologies VRA and VPW.

          Industry

          Fuel cell applications
          CFRP hydrogen high-pressure vessels for fuel cell applications

          Voith Composites works on the next generation of hydrogen high pressure (700 bar) vessels for fuel cell electric vehicles (FCEV). Nowadays, reducing process costs in combination with new vessel concepts is of decisive importance. At Voith Composites, the finite element method (FEM) and winding simulation, as well as accompanying quality management during development, ensure qualitative results. Fast development loops due to the short distance to the test facilities also support this.

          Go to the press release
          Paper Industry
          CFRP applicator beam for the SpeedSizer AT film application unit

          In the papermaking process, the SpeedSizer AT improves the paper characteristics, penetration and surface coverage in a targeted fashion. Classical applicator heads are built from stainless steel, steel or cast iron. Thermal influences cause deflections at the applicator head, which can result in poor CD profiles producing coated papers. The use of CFRP achieves optimal film application with outstanding CD and MD coat weight profiles throughout all operational conditions. With a CFRP beam, the systems needs no temperature-controlled heating system, which ensures dimensional stability at all. The results are optimal profiles over the entire life cycle and lower energy consumption.

          paper industry
          CFRP doctor blades

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          Paper industry
          CFRP rolls

          Guide rolls made of steel are often operated above their capacity limits, which can result in vibrations and thermal deformations. Unlike steel, the strength and rigidity of CFRP rolls can be adapted to the specific requirements without altering the installation space. Moreover, the much lower density ensures a significant weight reduction. CFRP components also offer a range of other benefits, like low thermal expansion or excellent running properties. Thus, composites are typically used for various guide rolls along the entire paper manufacturing process in the paper industry.

          CFRP drive shafts

          Due to its high specific stiffness and strength, CFRP is very well suited for use in drive shafts. The performance of the material often allows a reduction in the overall costs of the system; the one-piece design avoids cost-intensive bearing points. Due to the favorable ratio of stiffness to density, CFRP drive shafts achieve a significantly higher critical bending speed than steel shafts.

          Transportation
          CFRP blades for the Voith Inline Thruster

          In cooperation with Voith Turbo, blades for the Voith Inline Thruster (VIT) were manufactured from CFRP. This set a new standard for the coating quality of anti-cavitation coating. Moreover, the blades are characterized by a high UD proportion.

           

           

          Aerospace

          Structural component
          CFRP duct segment

          Voith Composites designs and produces components for the aerospace industry, including seat components, tanks, linings, overhead storages and ducts. With the use of carbon fiber, the shown duct segment is temperature-stable, high load capable and incredibly lightweight.

          Component
          CFRP water tanks

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          Talk to us about your vision!

          Not sure if your project can be realized with carbon fiber components? Contact our team of experts for a free consultation.

          Our preforming technologies

            Voith Roving Applicator

            Voith Roving Applicator (VRA)

            Voith Roving Applicator (VRA)

            The Voith Roving Applicator (VRA) is a fully automatic direct fiber placement machine with high, scalable lay-up rates. At JEC World 2017, the VRA technology won the JEC Innovation Award.

            The method uses cost-effective raw materials such as untreated rovings and binder powder to produce a near-net-shape dry stack as part of the fully automated preform production. The VRA produces components efficiently, inclusive of individual fiber distribution and local reinforcements.

            VRA Wins JEC Innovation Award 2017

            Voith Roving Applicator NextGen

            Voith Roving Applicator NextGen

            Voith Roving Applicator (VRA) NextGen

            Instead of applying a binder like the VRA from the first generation does, the VRA NextGen can impregnate the resin directly into the fibers. This further streamlines the process chain and makes it easier to handle workpieces – especially if they are manufactured within the same production line.

            Filament Winding Process

            Filament winding at Voith Composites

            Filament Winding Process

            The Filament Winding Process enables high precision for rolls and shafts: the fiber is unwound from a roving spool, led through a resin bath for impregnation and then wound onto the mandrel. The wound laminate is tempered in an oven to let the resin react and cure what gives the composite structure its stiffness and strength. Finally, the mandrel is pulled from the composite roll.

            Voith Prepreg Winding

            ​Voith Prepreg Winding (VPW)

            Voith Prepreg Winding (VPW)

            VPW is a winding technology for the mass production of composite preforms and components, which produces stacks especially efficiently. It processes several rovings at the same time, impregnates them with resin, and then uses a special winding process to produce two-dimensional preforms. These are preformed three-dimensionally and subsequently cured. Depending on the winding pattern, the winding process achieves a lay-up rate of up to 140 kilograms per hour.

            Different curing processes are possible, depending on requirements: (High pressure) resin transfer molding, wet compression molding or prepreg compression molding.

            Research and development

              We continue to enhance our expertise in numerous development projects – on our own and with research and industry partners.

              R&D and production center

              Voith Composites is the R&D and production center of carbon fiber-reinforced composites within the Voith Group. At two locations, our highly qualified experts develop machines for the manufacture of prototypes up to serial production. We are working with state-of-the-art development tools:

               

              • Design with CATIA and Inventor
              • FE simulations using ANSYS and Abaqus
              • Material analyses using DMTA, TGA, CT and microscopy
              • ThinPly

              Engineering

              Using our know-how from real-life customer projects and ongoing research, we provide strong support at every stage of the development phase. From the start, we offer feasibility and concept studies for composite parts, tooling and special machinery. Working at any depth of detail required, we develop our customer’s ideas using mechanical design (CAD) to structural and process simulation (FEA) to virtual process layup – always keeping composites-based design and cost-efficient manufacturing processes in mind.

               

               

              Project SMiLE

              The objective of the project System-Integrative Multi-Material Lightweight Construction for Electric Mobility (SMiLE) is to develop a lightweight construction concept completely aligned to the specific requirements of electric mobility. The structure of the project ensures that the results flow directly to the manufacturers along the supply chain into products that can be standardized and that are in demand by the respective downstream stages in the supply chain. The project SMiLE receives funding from the Federal Ministry of Education and Research.

               

              At the China Composites Expo 2018, the latest application SMiLE-Next Generation Hybrid Fiber Reinforced Floor Module was awarded with the CCE-JEC Innovation Award 2018. 

              Get in touch with our experts

                Our Composites Expert Team

                 

                t +49 89 32001800

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