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Fiberr Manufacturing Processes

Product Manufacture

Fiberr manufactures for our existing worldwide client base on a 105-acre site in Manisa, Turkey near the port of Izmir.    We are Turkey's largest composite manufacturer, and the only one that produces all forms of FRP.

Our manufacturing processes include:

  • Continuous Reinforced Thermoplastic Processing (CRTP) - Continuous Reinforced Thermoplastic Processing (CRTP) is an advanced manufacturing process that uses high-temperature and pressure to form reinforced thermoplastic sheets. In this process, a continuous sheet of thermoplastic resin is impregnated with chopped fiberglass, carbon fiber, or other fiber reinforcements. The sheet runs along a conveyor belt that forms the matrix into a continuous sheet of reinforced thermoplastic composite material. Once cooled and cut to size, the composite sheet can be used to create a variety of Fiber Reinforced Plastic (FRP) products, such as flat sheets, corrugated panels, and structural shapes.

  • Pultrusion - Pultrusion is a process used to produce reinforced composite materials, such as fiber-reinforced plastic (FRP). The process involves using a series of rollers to pull pre-impregnated fibers and resin through a heated die. The die is designed to shape the material as it passes through and produces a finished product with a consistent cross-section. The combination of heat and pressure created by the rollers and die allow for a strong bond between the fibers and the resin. The strength of the bond is dependent on the type of resin used and the temperature of the die. Additionally, in pultrusion, the rollers are able to apply tension to the fibers, which increases the strength of the material.

  • Injection Molding - Injection molding for FRP (Fiber Reinforced Polymer) is a process that involves heating fiber reinforcements like glass, carbon fiber, and aramid fiber in a matrix of polymers such as polyester, vinyl ester, and epoxy resin. The heated polymer is then injected into a pre-designed mold, where it cools and cures. During the cooling process, the polymer matrix and fibers become one solid, homogenous material with the strength and durability of both the polymer and the fibers. The resulting product is extremely strong and lightweight, making it ideal for a variety of applications.

  • Molded Grating Process - Molded grating is a process used to create fiberglass reinforced plastic (FRP) products that are stronger than traditional materials, such as steel and aluminum. The process involves combining fiberglass strands and a polymer resin to form a thick mat that is then heated and pressed through a die to create a grating product that has a predetermined pattern and thickness.  The molding process can be done in one of two ways: open molding or closed molding. In open molding, the mat is laid into an open mold and then heated and pressed together in the mold to form the desired shape. In closed molding, the mat is placed inside a closed mold and then injected with a resin and heated and pressed together in the mold to form the desired shape.  The finished product is then typically cured or hardened using ultraviolet light or other means before being removed from the mold. The finished product is a strong, corrosion-resistant FRP grating with a predetermined pattern and thickness.

  • Compression Molding - Using a press to form Bulk Molding Compound (BMC) plastic involves a precise and controlled manufacturing process. Firstly, BMC, a mixture of thermosetting resins, glass fibers, fillers, and additives, is pre-measured and prepared to achieve the desired material properties. The press, equipped with a mold cavity that matches the intended product's shape, is then preheated to the appropriate temperature. Once ready, the heated BMC is loaded into the mold cavity, and the press exerts high pressure to force the material to take the mold's shape and fill out all intricate details. The combination of heat and pressure promotes the curing of the thermosetting resin, creating a strong and rigid final product. After the curing time, the press is released, and the formed BMC plastic part is removed, followed by any necessary finishing touches. The process ensures consistency and high-quality output, making it a preferred method for manufacturing various components in automotive, electrical, and consumer goods industries.

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