Manufacturing Processes
Wausaukee Composites offers an array of fabrication processes in order to best suit your product specification, quality, fit, finish, and production volume requirements, including:
Open mold spray-up lamination process
Open molded hand-lay lamination process
Wind turbine nacelle base mold prepared for lamination
Mold storage warehouse at Gillett plant
Example of open-molded off-road truck hood final assembly
Image ofOpen Molding
Hand lay-up or spray-up application. Best for low-volume, large and/or complex components requiring one-sided finish. Can accommodate single or multi-piece molds. Preferred method for prototype development. Least expensive tooling option. Best for lower production rates – less than 1,000 parts per year.
Light Resin Transfer Molding (LRTM) production cell
Vacuum Assisted Light Resin Transfer Molding (LRTM) Process
Placement of glass reinforcement prior to LRTM molding process
De-molding LRTM part
Image ofLight Resin Transfer Molding (LRTM)
Preferred manufacturing method for composite components requiring two-sided finish at moderate production volumes. This vacuum assisted, closed-molded resin infusion process provides improved dimensional controls, tighter weight tolerances, increased strength-to-weight ratio in most parts, higher production velocity, and an improved manufacturing environment. Composite tooling is inexpensive relative to machined aluminum or steel tooling. Best suited for mid-volume production rates, in range of 500 to 5,000 parts per year.
Placement of re-usable silicone bag for Closed Cavity Bag Molding (CCBM) process
Introduction of resin in vacuum bag infusion molding process
Vacuum bag molding yields improved thickness controls and higher glass-to-resin ratio
Image ofVacuum Bag Infusion Molding
Vacuum assisted, closed-molded resin infusion process with a flexible sheet or re-usable bag providing the B-side surface compression. This process yields increased laminate compression, a higher glass-to-resin ratio, and improved strength to weight performance. Recommended for products with high strength to weight requirements, or with slight design returns, edge overhangs, or high draft angles that would cause die-locks on rigid B-side mold surfaces. Best suited for mid-volume production rates, in range of 500 to 5,000 parts per year.
RTM-molded reinforced truck hood frame
Resin Transfer Molding (RTM) structural glass preform
Robotic application of fiberglass reinforcement to the mold cavity for VARTM molding
Preparing the Vacuum Assisted Resin Transfer Molding (VARTM) production press
Image ofResin Transfer Molding (RTM)
Excellent method for structurally reinforced parts requiring two-sided finish. Produces parts with highly controlled thickness and cross-sectional tolerances. Wausaukee Composites utilizes both continuous fiber and robotic (RimFire™) pre-forming of RTM structural glass. More complex, cored "sandwich" structures also are available. Best suited for structural plastic components in moderate to high production volumes - 1,000 to 50,000 parts per year.
Reaction Injection Molding (RIM) of structural urethane headlight bezel
Two-component urethane injection system, and RIM press
Image ofReaction Injection Molding (RIM)
Higher production rate process producing high gloss (Class A), two-sided cosmetic finish with excellent surface quality. Superior control of all dimensional tolerances. Cost effective piece parts good for structural and non-structural applications. Use of pigmented resins or in-mold coatings are possible. Tooling is less expensive than capital intensive, high volume press molding processes. Best suited for moderate to high production volumes (1,000 to 100,000 parts per year).
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Rotomolding
Rotational molding of plastic resins to create hollow tanks and fluid reservoirs with constant wall thickness, using bi-axial and rock-and-roll rotomolding machines. Inserts, threads, bosses, undercuts, handles, may be in-molded. Plastics resin options include: Low Density Polyethylene (LDPE); Linear Low Density Polyethylene (LLDPE); Medium Density Polyethylene (MDPE); High Density Polyethylene (HDPE); Cross Linked Polyethylene (XLPE); Polypropylene (PP); PVDF; and CBT / PE.
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Liquid Composite Molding (LCM)
Higher production rate process producing precise dimensional control. Utilization of preforms and "sandwich" structure possible. Pressures allow epoxy tooling to be utilized for lower end of volume range. At higher range, tooling is less expensive than other compression molds. Best for structural and non-structural parts with non-finished surfaces. Best suited for moderate to high production volumes (1,000 to 100,000 parts per year).
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Sheet Molding Compound (SMC)
Press molding process delivering high surface quality. Allows high molded-in detail, including ribs, bosses, inserts, and moderate thickness variations. Excellent temperature and fire resistance. Cost effective piece parts good for structural and non-structural applications. Best suited for moderate to high production volumes (5,000 to 100,000 parts per year).
Soft touch urethane material forming
Soft touch urethane mold preparation
Soft touch urethane interior dash components
Soft touch urethane interior cab component
Image ofSoft-Touch Urethane
Vacuum forming / low-pressure urethane casting process producing soft-touch a-side surface and developed interior finish. Designed thickness variations and integrated inserts possible. Highly flexible material allows deep draw parts. Low pressures allow inexpensive tooling. Well suited for moderate production volumes (500 to 10,000 parts per year).
CNC robotic gel-coat application for highly cosmetic surface finishes
Precise CNC robotic router trim of truck hood in vacuum holding fixture
Robotic application of fiberglass reinforcement for VARTM perform
Robotic drilling and routing of secondary features
Robotic application of adhesive for internal frame reinforcement
Precision part edge trimming by CNC waterjet robot in vacuum holding fixture
Image ofRobotic Operations
Wausaukee Composites employs robotic automation throughout its manufacturing plants and processes. Computer Numerically Controlled (CNC) robotic operations are used in gel-coat application, chopped reinforced fiber application, waterjet cutting, trimming, drilling, routing, and secondary adhesive application and bonding processes.
Gel coat application on mold surface
Robotic in-mold primer gel coat application
Sandable primer paint booth
Two-tone textured painting of medical equipment coverset
Conveyor-driven top coat paint line
Image ofIn-Mold Gel Coating and Post-Painting
Wausaukee Composites provides a variety of cosmetic surface coating options, including in-mold gel coating, sandable primer coating, textured painted coatings, industrial quality painted surfaces, and Class-A top coated painted surfaces.
Truck hood assembly for shipment to OEM customer facility on collapsible/returnable racks
Installation of grills and vent stacks on construction truck hood
Final finishing on fully assembled wind turbine spinner hub
Secondary installation of electronic circuit boards and cable harnesses
Medical equipment secondary hardware assembly
Image ofPost-Production Assembly
Finished components may be packaged individually, or may also be pre-assembled into subcomponents or fully assembled product configurations. The finished product will be packaged to the customer's specifications with disposable packing materials, re-usable packaging, returnable containers, or custom-designed rack systems. For complex multi-component systems, we will work with your product engineering and operations teams to develop an optimal packaging and crating system that will help optimize the unloading and assembly procedures that take place at your facility.
