Resources

of

HD Composite Zrt.

Reinforced with Innovation

HD Composite is a 100% Hungarian-owned company, based in Budapest, specialized in designing and

manufacturing of fiber-reinforced composites as well as providing related services. We are working not

only with already well-established processes, like compression molding, RTM, or hand lamination, but in

the frame of our research and development programs we are dealing with new, forward-thinking complex

technologies like combined T-RTM, which may determine the future of the industry.

We are focusing primarily on automotive, energy and defense sectors. Our portfolio covers engineering

services, like mechanical calculations, product- and mold- design, as well as development of automated

polymer composite manufacturing lines.

Our experienced team is committed for continuous improvement and working hard on the above-mentioned

tasks to leave a mark on the industry. HD Composite is going to implement new QM and ERP systems and

invest more than 4000k EUR in equipment and facility extension in 2020, by creating a new factory in

Várpalota, Hungary.

HD Composite

Our current development and

production facility is located in

Budapest and consists of:

• 526 sqm production area with 4 x

3,5 t overhead cranes,

• 450 sqm climatized development

area

• 180 sqm lamination workshop and

• 180 sqm grinding workshop.

All buildings are equipped in

accordance with local environmental

regulations.

The chemical warehouse is an

external tempered ATEX building.

HDC facility in Budapest

Polyester resin mixing and dosing system

(in operation in HDC from January 2021)

System parameters

500 Liter resin tank with autom. refilling system, agitator and heater

20 Liter catalyst tank

Servo controlled Catalyst/Hardener Ratio system

Remote Pendant Operator Screen

On-board Vacuum System

In-line PID Resin Heater

Catalyst/Hardener and Resin Flow Measurement System

Vacuum level Monitoring with Pre-Injection Vacuum Test

Data Recording (USB/UTP)

Static mixing head with automated cleaning system

High-flow Head option

Epoxy resin mixing and dosing system

System parameters

200 Liter resin tank with automated refilling system, agitator and

heater

Additive (ATH) dispenser

Degasing

2 x 60 liter hardener tanks

Servo controlled Resin/Hardener Ratio system, 100:10 – 100:100

Remote Pendant Operator Screen

On-board Vacuum System

In-line PID Resin Heater

Hardener and Resin Flow Measurement System

Vacuum level Monitoring with Pre-Injection Vacuum Test

Data Recording (USB/UTP)

Static mixing head with automated cleaning system

High-flow Head option

(in operation in HDC from January 2021)

Vacuum pumps, mold tempering units

System parameters

Nominal pumping volume 63 m³/h

Ultimate pressure 0,1 hPa (mbar)

Vacuum tank 120 l

BUSCH R5 RA 0063 F

(in operation in HDC)

WittmannTEMPRO plus 250

System parameters

Heating capacity max. 12 kW

Pump capacity (50 Hz)1 kW, max. 7 bar,

max. 45 l/min

Maximum temperature 250 °C

Gelcoater

System parameters

Continuous adjustable catalyst ratio

Recirculation of gelcoat and catalyst

Static mixer in the gun

Reduced solvent consumption

Flushing with a mix of solvent and air

Reduced material wastage

Even flow of catalysed material

Light weight spray gun

Pumps can be added as needed

Capacity: Up to 6 litres / min, depending on viscosity,

hose length/ diameter and nozzle orifice

Max. working pressure: 144 Bar (2169 psi)

MIPG-24/HV Multicolour Gelcoater(in operation in HDC)

System parameters

Width/depth/height (mould carrier 0° position

open)

2,340 / 3,270

/ 4,280 mm

Mould clamping platen bottom (FAPU)

Platen length 1,300 mm

Platen depth 1,300 mm

Compression injection stroke 0 - 3 mm

Compression speed 0.5 - 3 mm/s

Upper mould clamping frame (FAPO)

Platen length max. 1,300 mm

Platen depth min. 700 mm

Platen depth max. 1,300 mm

Parallel stroke (hydraulic) 250 mm

Clamping force 3,800 KN

Weight of mould total max. 7,000 kg

Weight of upper mould half total max. 3,000 kg

HP RTM Mould Carrier

(in operation in HDC)

Power tools and equipment for mold manufacturing

Optimum S 181 G

industrial cutting

machine

Weld-Impex

Weldi-MIG 300

welding machine

Scheppach

BASA3 Band saw

JET Dust

collector

(in operation in HDC)

and many more…

System parameters

Cut Length (mm)- Machine 3100

Length (mm)- Pick-off Table 3100

Cut Width (mm) 3200

Performance (Watts) 2500

Cutting tools

• drag knife,

• rotating disc,

• oscillating knife,

• power milling

Identification of cut parts Ink jet printing

Blackman & White VERSA TECH 2 ™

Digital Flatbed Cutter

Automated Cutting Machine

(in operation in HDC)

Axes strokes(mm)

Quick

positioning

speed

Quick

acceleration

Bi-directional

accuracy (P)

Unidirectional

repeatability

(Ps)

X = 15.500 85 m/min 2,0 m/ s2 0,112 mm 0,040 mm

Y = 4.000 85 m/min 2,0 m/ s2 0,050 mm 0,025 mm

Z = 2.500 45 m/min 3,0 m/ s2 0,045 mm 0,021 mm

C = +/- 300° 9000°/min 500°/s2 26 arcsec 16 arcsec

A = +/- 110° 9000°/min 500°/s2 26 arcsec 16 arcsec

Main Characteristics

Electrospindle power (S1) 20 kW from 10.600 rpm/min.

Maximum revolution speed 24.000 rpm

Connection shaft HSK 63 A

Torque (S1) 63 Nm

Carbon fiber dust protection Yes

CMS CONCEPT 40/155/25 PX5

High Speed 5 axes CNC Machining Centre

(in operation in HDC from Nov. 2020)

Creaform MetraSCAN 3D

portable optical CMM 3D scanner

System parameters

Accuracy Up to 0.040 mm (0.0016 in.)

Volumetric Accuracy0.060 mm + 0.025 mm/m

(0.0024 in + 0.0003 in/ft)

Resolution 0.050 mm (0.0020 in.)

Measurement Rate 205,000 measurements/s

Part Size

Range (recommended)0.2–6 m (0.7–20 ft.)

Scanning Area 225 x 250 mm (8.8 x 9.8 in.)

Light Source 3 laser crosses

Certifications

EC Compliance (Electromagnetic

Compatibility Directive, Low

Voltage Directive, RoHS 2

Substance Restrictions

Directive), IP50, WEEE

3D scanning system

(in operation in HDC from January 2021)

Curing and drying oven

System parameters

Length (mm) 5500

Height (mm) 2200

Width (mm) 2200

Max temperature (°C) 160

Accuracy ± 2°C

Heating speed 3°C/min.

Control unique treatment steps

Vaccum and press. air manifolds 12 pcs.

Forced cooling by venting

(in operation in HDC from January 2021)

T-RTM mixing and metering machine

System parameters

Dosing by gear pumps

Raw material tank 2 x 25 l; 0-10 bar

Capacity level measurement min. 1%

Temperature control max. 150 °C (200 °C)

Vacuum pump min. 3 mbar

Mixing head, mix ratio 5-95%

Injection flow rate 2 x 6,25-135 g/s

Insulated meter pipe; heating jacket max. 3 bar; max. 150 °C

High pressure metering pump max. 200 bar

(in operation in HDC)

KraussMaffei Rim Star Nano 8/8

T-RTM mixing and metering machine

System parameters

Dosing By piston pumps

Raw material tank 2 x 25 l; 0-10 bar

Capacity level measurement min. 1%

Temperature control max. 150 °C (200 °C)

Vacuum pump min. 3 mbar

Mixing head, mix ratio 5-95%

Injection flow rate 2 x 0,65-62,5 g/s

Insulated meter pipe; heating jacket max. 3 bar; max. 150 °C

High pressure metering pump max. 200 bar

(in operation in HDC)

KraussMaffei Comet 0,2 - 4 Nano

Automated RTM preforming system

System parameters

Preform 3D geometry max. 1250 x 1250 x 250 mm

Preform thickness max. 15 mm

No. of preforming tools 2 (180° turntable)

Upper tool size; mass max. 1300 x 1300 x 800 mm; 300 kg

Lower tool size; mass max. 1300 x 1300 x 700 mm; 300 kg

Tool complexity 16 different cylinders

Preforming temperature max. 150 °C

Manipulators 2 x 6 axis Fanuc m-710ic/45m robot

Reach of manipulators 2606 mm

Load capacity of

manipulators45 kg

(in operation in HDC)

Fanuc, Siemens, HDC

• Computer-aided design

• 3D scanning

• Prototyping

• Mold- and tool design

• Unique machine parts

• Special purpose machines and equipment

• Automated process line development

• Complex composite parts

Software systems, engineering capabilities

• Computer-aided engineering

• Engineering calculations

• Finite element simulation

• Structural composite parts analysis

• Composite optimization

• Bonded joints simulation

• Specimen tests

• Validation

ERP

Management Systems, Certificates

Certified Systems

ISO 45001:2018

ISO 14001:2018

ISO 9001:2018

Our recent expansion is in Várpalota, Hungary.

The phase 1 construction starts in spring 2020 and

will take app. 12 months on our 123 000 sqm

industrial land.

New composite R&D and production center

Phase 1. facility consists of:

• 2500 sqm production area

with 2 x 10 t overhead

cranes,

• 220 sqm storage

• 450 sqm office

• 90 sqm gel coating cabinet

• 90 sqm post processing /

grinding workshop.

• etc…