Malitronic® MULTIAXIAL
flexible and highly productive approaches to the
production of semi- finished carbon-fibre-fabrics
Swen Petrenz / key account manager carbon technology
KARL MAYER MALIMO Textilmaschinenfabrik GmbH / Chemnitz
Content:
- buisness unit technical textiles – overview portfolio
- summary
- the Karl Mayer company
flexible and highly productive approaches to the
production of semi- finished carbon-fibre-fabrics
- process and potentials to create Non-Crimp-Fabrics (NCF)
Shepshed
Obertshausen
Chemnitz
Mönchengladbach
Hongkong
Changzhou
Fukui Mezzolombardo
Greensboro
KARL MAYER Worldwide
Company Overview
Uzwil
• Multiaxial machine
• Biaxial machine
• Weft insertion machine
• Stitch bonding machine
For the production of:
• Composites
(fiber glass and carbon)
• Coated fabrics
• Nonwovens
• Lace machines
• Tricot machines
• Raschel machines
For the production of
• Rigid, elastic, and
semitechnical fabrics
• Warpers for warp
knitting
• Beaming machines
• Sectional warping
machines
• Warp sampling
machines
• Sizing machines
• Assembling machines
• Indigo dyeing range
Machine
• Creels
• Wide range of
Technologies
• Parts manufacturing
• CFRP competence
Tailor-made solutions, worldwide service network and training academies in Europe and China
KARL MAYER Business Units
Warp Knitting
Warp Preparation
Technical Textiles
Parts and Components
Portfolio KARL MAYER MALIMO
Warp knitting machines with weft insertion Stitch- bonding- machines
RSP MSUS
RS MSUS-G
RS MSUS-V
RS MSUS
HKS MSUS
continuous weft
insertion
cut to length weft insertion
BIAXIAL
MULTIAXIAL
Malitronic®
BIAXIAL
MULTIAXIAL
Wefttronic®
• CFRP has already shown their lightweight potential
• Automation and series manufacturing is necessary for an ecological and
economical production
• The biggest potential savings are gained by reduction of process costs
Motivation
Motivation
General Process Flow - RTM
source: krauss maffei
fabric
fabric preform
moulding injection
Component part
resin
Motivation
General Process Flow - RTM
source: connectra
fabric
fabric preform
moulding injection
Component part
resin
Conclusions about NCF
• Significant cost savings during storage and curing process
– No need for tight climate controls during storage and downstream processes
– No need for expensive autoclave process to cure parts
• High grade of playability
– Individual carbon layers can shift to one another
• Super large and complicated shapes are possible
– No parts size restrictions due to autoclave sizes
• One step process from the carbon package to the fabric is possible
• High grade of flexible and fast fabric design changes
continuous weft insertion cut to length weft insertion - Cut & Lay
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
• raw material is cut to length and cutted tape-
sequences are fixed in a PIN- field- system, what
contineously moved to the knitting unit
• mainly to produce carbon fibre products
• light- weight to heavy grammage
• 3K up to 50K (60K)
• Less waste with a high output
high fabric quality
high output up to 4,8 m/min
Malitronic® MULTIAXIAL
Malitronic® PIN- PIN
continuous weft insertion
Malitronic® MULTIAXIAL
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
Malitronic® PIN- PIN
continuous weft insertion
Malitronic® MULTIAXIAL
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
Malitronic® PIN- PIN
continuous weft insertion
Malitronic® MULTIAXIAL
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
Malitronic® PIN- PIN
continuous weft insertion
Malitronic® MULTIAXIAL
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
Malitronic® PIN- PIN
continuous weft insertion
Malitronic® MULTIAXIAL
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
Malitronic® PIN- PIN
continuous weft insertion cut to length weft insertion - Cut & Lay
• raw material is endless fixed in PIN-
PIN transport- system, what
continuously moved to the knitting unit
• Glas, Aramid, Carbon, Basalt, …
• hybrid- structures possible
• medium to heavy grammage
• 3K up to 24 K (50K)
• raw material is cut to length and cutted tape
sequenses are fixed in a PIN- field- system what
contineously moved to the knitting unit
• mainly to produce carbon fibre products
• light- weight to heavy grammage
• 3K up to 50K (60K)
• Less waste with a high output
high fabric quality
high output up to 4,8 m/min
Malitronic® C&L
Malitronic® MULTIAXIAL
• High performance
• up to 600 mm weft insertion bandwidth
• up to 2.000 rpm in knitting process
• up to 4.8 m/min fabric throughput
• High grade of fabric quality
• High flexibility in machine specification and fabric construction
due to modular machine concept
• High grade of user- friendliness
• Exact reproducibility of fabric specifications
Malitronic® MULTIAXIAL C&L (Cut & Lay)
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Substrate fabrics Loose structures
Online – spreading Offline – spreading
Carbon Fiber Roving
• spreading during production
• direct unwinding from the creel
• bandwidth up to 200 mm
• 3K up to 24 K (50K)
possible Output: up to 1,6 m/min
• separate spreading process with special equipment
• spread tape as reference material
• bandwidth up to 600 mm
•12K up to 50K (60K)
possible Output: up to 4,8 m/min
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Carbon Fiber Roving
Online – spreading Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Carbon Fiber Roving
Online – spreading Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Carbon Fiber Roving
Online – spreading Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Fiber Spreading Line
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Details from producing tape in the fiber spreading line
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Details from producing tape in the fiber spreading line
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Details from producing tape in the fiber spreading line
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Details from producing tape in the fiber spreading line
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Carbon Fiber Roving
Online – spreading Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Carbon Fiber Roving Loose structures Substrate fabrics
foils nonwoven others
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
possible additional substrate fabric feeds
Nonwovens / Foils / Others
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Substrate fabrics Carbon Fiber Roving Loose structures
Chop Powders Others
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
possible additional loose structure feeds Chop / Powders / Others
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Substrate fabrics Loose structures
Online – spreading Offline – spreading
Carbon Fiber Roving
Weft insertion
130“ 133“ – 80“ max. ± 45°
100” 103” – 50” max. ± 45°
60” 65” – 30” max. ± 30°
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Offline – spreading
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
High flexibility –
Quick change of weft angle
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Fabric transport Elements
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
• reinforced, reliable feeding
• fixing of tapes in multiplex Pin - System
Transport Chain
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
• fully support of weft plies up to
the knitting unit
• synchronized movement to the
transport chains
Conveyor Belt
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
High flexibility –
Quick change fabric width
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Possible space for creel
Warp - yarn feeding from tape reel –
supplied from fiber spreading line
Warp - yarn feeding from creel
Working from pre-spread tape reels
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
for tapes produced on fiber spreading line
rolling up device for separation paper
ST -Unwinding Frame
for Tape Reels
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
position of knitting yarn warp beams
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
With monitoring systems for yarn tension and end breaks
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
position of stitching head
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
-45°
90°
+45° 0°
Substrate
coating
knitting
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
2
3
5
4
6
7 1
Material flow
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
2
3
5
4
6
7 1
Material flow
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
2
3
5
4
6
7 1
Material flow
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
position for selvedge / panel cutting and suction unit
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Cutting and Suction
• sheer cutting system
Tidland
• suction nozzle connected
to central vacuum
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Cutting and Suction
• sheer cutting system
Tidland
• suction nozzle connected
to central vacuum
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
position for take-up and batching
Batching device
Input
material
Weft
insertion
Fabric
transport
Warp-yarn
feeding
Knitting yarn
feeding
Knitting
process
Take-up
batching
Cutting/
suction
Future Machine Integrations
• Advanced fabric defect detection for all layers
• Inline shape cutting processes
• Pre-adherence of thermoplastic films / layers
• Automated roll / piece packing and transport
• Inline connection to downstream processes
Malitronic® MULTIAXIAL strong points
High output
High fabric quality in laying:
High fabric quality:
High flexibility:
less weft waste:
modular concept
high OEE:
Mauersbergerstraße 2
09117 Chemnitz, Germany
Phone: +49 (0)371 8143-264
FAX: +49 (0)371 8143-32-264
Swen Petrenz key account manager carbon technology
KARL MAYER MALIMO
Textilmaschinenfabrik GmbH - Germany BUSINESS UNIT TECHNICAL TEXTILES
www.karlmayer.de