Processes & Materials

Gelcoating: Brush or spray application of pigmented polyester resin to improve the appearance and weatherability of molded composite parts. Gelcoat is typically applied 0.015 to 0.022” thick and allowed to cure prior to introduction of the resin/reinforcement matrix. Like paint, virtually any color can be supplied.

Resin Transfer Molding (RTM /Lite RTM): A process using a two-sided mold set that forms both surfaces of the part. The lower side is a rigid mold; the upper side can be a rigid, semi-rigid or flexible. The two sides fit together to produce a mold cavity. In RTM the reinforcement materials are placed into this cavity dry and the mold set is closed prior to the introduction of matrix material. Resin transfer molding includes numerous varieties which differ in the mechanics of how the resin is introduced to the reinforcement in the mold cavity. These variations include everything from vacuum infusion to vacuum assisted resin transfer molding. This process can be performed at either ambient or elevated temperature and parts can be built with or without gelcoat.

Vacuum Infusion Molding: A subset of RTM where the reinforcements and core materials are cut, fitted, and adhered in to place. Resin distribution medium is laid out on top of fiberglass and the inside of the mold is covered with a sheet of loosely fitting plastic sheeting that is sealed in to the mold perimeter with sealant tape. Using the vacuum pump, all the air is removed from the job which compresses the dry stack of reinforcement fabrics. Through a series of feed hoses sealed into the bag, resin is then sucked via the vacuum from mixing containers. The resin travels through the mold saturating the entire stack of dry laminate material. The vacuum is maintained until the resin has cured. While cycle times are longer than with RTM or Light RTM, lower weight parts and better strength to weight ratios can be achieved.

Open molding A process using a rigid, one sided mold which shapes only one surface of the part. Part thickness is determined by the amount of material placed upon the mold. Reinforcement materials are placed manually by hand or by chopper gun (spray-up). Reinforcements are typically glass fiber roving or mats. The resin matrix is typically polyester but can be vinyl ester or epoxy and is spray applied with a chopper gun or manually using bucket, squeegee, and brush.

Composite Tooling:

Simple patterns and mold manufacture for both internal and third party end use is done on site in a separate environmentally controlled area. Attbar partners with Pattern Makers to build more complex geometries.  Attbar works with 2-D drawings as well as 3-D CAD files and models.

Bonding & Assembly:

Attbar will source and install your component parts to supply a complete assembly.  Hinges, latches, and other hardpoints can be attached with traditional fasters or with structural adhesives.  Sub-component and reinforcement composites can also be bonded together to create the final part.

Surface Coating:

Attbar will use HVLP spray equipment to apply industrial and automotive grade paints and coatings to your completed product; we can apply acrylic, epoxy, or urethane coatings to your parts to assure your completed product exceeds your surface coating specifications.
 

Carbon Fiber & Aramid Applications:

Attbar manufacturers numerous products for customers that utilize the physical strengths of Carbon Fiber and/or Aramid; these two products or combinations thereof are frequently used by our customers in the medical, health, ballistic, military and sporting industries.  If you have a particular application that you think would benefit from the properties of either Carbon Fiber or Aramid, contact us.

Carbon fiber is most notably used to reinforce composite materials, particularly the class of materials known as carbon fiber reinforced plastics. Carbon fibers find many uses because of their strength, stiffness and light weight. The resin matrix is typically vinylester or epoxy, but polyester can be used.   Some composites contain both carbon fiber and other fibers such as Kevlar, aluminum and fiberglass reinforcement. Sometimes referred to as graphite reinforced plastic or graphite fiber reinforced plastic.

Aramid fibers are a class of heat-resistant and strong synthetic fibers. They are commonly used in aerospace and military applications, for ballistic rated body armor fabric, and as an asbestos substitute. The name is a shortened form of "aromatic polyamide". They are fibers in which the chain molecules are highly oriented along the fiber axis, so the strength of the chemical bond can be exploited.

Fiber Reinforced Thermoplastic Molding: 

Commercially known as Polystrand™, fiber reinforced thermoplastic represents the next generation of fiber-reinforced polymer composite.  The material system combines continuous structural E-Glass, S-Glass, and Aramid Fibers.  Unidirectional tapes and X-ply continuous rolls can be reformed through high temperature processing to create a new family of end-use applications.  Polystrand™ makes a unique composite material by its use of oriented continuous fibers in a matrix of thermoplastic polymers.  The resulting structural composite has many advantages compared to traditional thermosetting polymer composite matrices