The AIRBUS Defence and Space GmbH (formerly EADS) patented Vacuum Assisted Process (VAP®) uses the properties of modern, semi-permeable membrane systems in highly developed textile composites to apply the effect of a vacuum to the entire surface of a component. This “vacuum assist” ensures that trapped air and gas can be reliably and efficiently removed during resin infusion.
VAP® stands for
Functional Principle
The Vacuum Assisted Process (VAP®) is a technique to manufacture composite parts using vacuum injection; it applies membrane-assisted low-pressure infiltration.
The surface of the part to be infiltrated with resin is covered with a flexible membrane system. The membrane is permeable to gas but impermeable to resin. When resin is infiltrated into the part inside the membrane, the latter keeps the resin inside the matrix and away from the vacuum duct. Yet, aided by the low pressure in the vacuum duct, trapped air and gas can still escape through the membrane’s micro-permeability and are purged via the textile layer. The vacuum acts uniformly, so purging takes place across the entire contact surface between part and membrane, during and after infiltration.
VAP® – Benefits
Easy implementation, as existing infusion tools and materials may be utilised.
Excellent component quality without dry spots.
Less re-working needed as result of high component quality.
Low laminate porosity due to efficient purging of air and gas through the VAP® membrane during and after infiltration.
Accurate control of fibre volume content.
Minimum resin waste, the needed amount of resin can be calculated in advance.
Homogeneous fibre volume content due to uniform vacuum across entire surface.
No thickness fluctuations and variations in component.
Easier flow front management because of less critical inlet distribution strategy.
Reduced cycle times due to faster, vacuum-assisted infiltration process.
Potential for higher component integration.
Consistently stable and controlled process, offers high process reliability and reproducibility.
Better economy, especially compared to autoclave processes.
Minimum investment needed.
Prepreg vs. VAP® – a Comparison
Prepreg
LOGISTICS
- Transport and storage refrigerated/freezer
- Shelf life limited
TECHNIQUE
- Lay-up – drapability limited
- Multi-stage process / Debulking
- Porosity ca. 2 % (Airbus allowables: 2,5 %)
- Limited material variety/selection
CAPACITIES
- Long & high-energy process cycles
- Capacity increase is complex & costly
VAP®
LOGISTICS
- Transport and storage at room temperature
- Longer shelf life
TECHNIQUE
- Lay-up – drapability improved
- “One-shot” process
- Porosity down to 0,15 % / Degassing during infusion
- Almost unlimited variety of technical textiles
CAPACITIES
- Fast & low-energy process
- Capacity increase is fast, easy & inexpensive
VAP® Functional scheme
VAP® – Patented from AIRBUS Defence & Space GmbH (formerly EADS) – German Patent DE 10013409 – Inventor: Stefan Utecht, Franz Stadler, Jürgen Filsinger, Torsten Lorenz
RAM
Custom Stealth Technology made in Germany
When submarines surface, they find themselves in a particularly dangerous situation.
The masts, mast heads and other components on and above the sail are visible above water and can therefore also be detected by radar systems.
To tackle this issue, COMPOSYST designed its own materials more than a decade ago, which – with the appropriate stealth or RAM technology (Radar Absorbing Material) – enable submarines to remain largely invisible, even above the waterline.
For this purpose, COMPOSYST offers two implementation options:
- Fairings for inner steel mast structures to prevent detection by radar systems
- Complete development and construction of entire mast systems made of FRP, which, in addition to being invisible for radar systems, also reduce weight and thus lower the center of gravity. This saves material and manufacturing costs while improving the stability of the vessel
Well-known companies already rely on the expertise of the European market leader COMPOSYST and their many years of experience with the concrete and reliable implementation of such technological challenges.
All benefits at a glance:
- Own design and production of active radar absorbing materials and structures
- Development and implementation of lightweight components in existing naval systems
- Adapted geometry and materials for radar absorption
- Decades of experience with marine radar systems
- Leading supplier in the European market for radar absorbing structures and materials
- Cost reduction
– through lower production costs
– through weight savings - Improved stability
3D Printing
Yesterday Milling – Today just print
COMPOSYST is a full-service provider. The time-intensive production of precision tooling becomes simplified by our in-house 3D printer throughout the entire process.
Thereby operations become additionally more sustainable, faster and cost-efficient.
COMPOSYST creates your required tools, components and structural parts individually and tailormade with its 3D printer.
You provide the geometry – we deliver the part.
The printer‘s build chamber (XYZ) with 1000 x 1000 x 1000 mm enables the production of large components in one fell swoop. With the double extruder you can use two individuel materials simultaneously.
COMPOSYST prints components and structural parts – without additional manufacturing steps or additional tooling, which makes the process even more ecological. We use pure (PLA, ABS, PA, PP, PC…) or fibre-reinforced (i.e. carbon or glass fibre) thermoplastics especially for components.
Benefit from our many years of experience: we choose the right material for the individual requirements of your component.
Your benefits:
- Cost and time savings through radically faster and more flexible production
- Sustainability: avoid wasteful substractive processes (i.e. milling) and move on to additive manufacturing with 3D printing
- Changes are significantly easier, save time and money by recycling the materials
- Budget-friendly production of prototypes and/or individual pieces (small editions also possible)
- Rapid prototyping: From the first idea via CAD construction and 3D printing to finished product in no time and with a lower budget
- Save on storage costs: just the digital data needs to be saved