Development and production of long-fiber-reinforced thermoplastic parts

Weber Fibertech develops and produces long and continuous fiber-reinforced thermoplastic parts. Medium and large-area plastic parts are produced using the D-LFT process in combination with, for example, organic sheets, UD tapes or tape fabrics with glass or carbon fibers. In addition, Weber Fibertech also uses the proprietary and patent-protected E-LFT process. These technologies enable the development and cost-effective production of very lightweight components with high strength, maximum rigidity and outstanding mechanical properties.

Key technology E-LFT

In the search for processes that solve the conflicting goals of stiffness, strength, long-term stability, weight and cost better than conventional materials, we have moved away from traditional approaches. The result is the E-LFT process, which we have made ready for series production after 10 years of research and development work. In combination with organic sheets, UD tapes and continuous fiber fabrics based on glass or carbon, this process now makes it possible to produce high-strength components at a reasonable cost. This means that we are ideally equipped for weight reduction in a wide range of applications.

Are you looking for a competent partner for lightweight construction? Then get in touch with us, our experts will explain the possibilities and potential for cooperation in a personal meeting.

Friedbert Schmitt, Managing Director

E-LFT Process

The combination of EF and LFT to E-LFT

In the search for processes that solve the conflicting goals of stiffness/strength, long-term stability, weight and cost better than conventional materials, we have moved away from traditional approaches. The result is our E-LFT process, which WEBER FIBERTECH has made ready for series production after 10 years of research and development work.

The process is based on long-fiber thermoplastic technology, which gives design and construction a great deal of freedom. Continuous fibers are embedded in this basic structure for structural reinforcement, giving the component strength and even crash safety. In addition to the freedom of design, the developer has the option of integrating functional elements directly into the process, thereby saving assembly and testing steps.

The result is components that weigh up to half as much as today's components at comparable costs and with comparable or improved safety, depending on material utilization.

High volume production

WEBER FIBERTECH has set up a modern and fully automated production facility at its production plant in Markdorf, where components up to 2 m² in size can be manufactured. Over one million parts produced prove the absolute suitability of this innovative lightweight construction technology for series production. The compounding integrated into the production line makes WEBER FIBERTECH very flexible in adapting the material - precisely to the specific requirements of the component - and thus expands the wide range of possible applications.

In addition to the automotive industry, this lightweight construction technology is also very popular in the aircraft industry, the construction and transportation sectors and in mechanical engineering. Our technology is also in great demand for electrical appliances, engine construction, agricultural technology and alternative energy systems.

Process development

Process development and component behavior as core competence:

Feasibility study Rough structural concept, target prices and deadlines
Project planning Efficient provision of the desired services
Popology optimization Detailed structural concept, rough dimensioning
Component design Secured structural concept
FE calculation Efficient provision of the desired services
Component design Representation of design, weight, geometry and function
Tool design and production Prototype and series tools, operating equipment
Sample production Pre-series samples produced in an automated process
Component testing Tensile tests, drop tests, slide tests
Series production Production of E-LFT components in medium to large quantities

Best solution

From idea to series production

You formulate your request, outline your idea - we look for the best solution. We develop your component, carry out feasibility studies on the basis of detailed calculations and simulations, optimize your component both technically and commercially, create initial demonstration samples, provide you with testable near-series prototypes, carry out component tests and supply you with small, medium and even large quantities in series.

For our customers, this means that we provide them with our many years of expertise in lightweight construction so that they can achieve their goals in terms of weight reduction, quality and cost optimization.

Production process

Economical production technology with short cycle times

The process is based on long-fiber thermoplastic technology, which gives design and construction a great deal of freedom. Continuous fibers are embedded in this basic structure for structural reinforcement in the areas required for the respective load cases, giving the component strength and even crash safety. In addition to the freedom of design, the developer has the option of integrating functional elements directly into the process, thereby saving assembly and testing steps. The result is structural components that weigh up to half as much as today's components at comparable costs and with comparable or improved safety, depending on material utilization.

Technological processes

Overview of technologies

LFT and DLFT

Production of long-fiber-reinforced plastic parts using the direct process.

E-LFT

Patent-protected in-house development for the cost-effective production of very lightweight, high-strength plastic parts. Surface or locally reinforced with organic sheets, tape layers and UD tapes.

Combination of processes possible

E-LFT Hybrid

Plastic parts with local metal reinforcements. Form-fit connection between plastic and metal. Forming of the metal blank and shaping of the plastic in a one-shot process in one tool.

E-LFT decor

Optical structural parts with grain structure, fabrics, fleeces, felts and foils, produced in a one-shot process.

More scope for design, construction and production

Advantages of the D-LFT and E-LFT technology

Weight reduction

Weight reduction through high strength and rigidity of components.

Economical lightweight construction

Cost advantages through local reinforcement only in the areas required for the respective load cases.

Higher strength

Genuine long fibers with fiber lengths of more than 10 mm in the plastic part through gentle direct processing of the fibers, resulting in higher component strength.

Proven welding and bonding technologies

Ideal for shell-shaped structural parts.

Lower tool costs

Significantly lower tool costs compared to injection molding with comparable cycle times. Process can be used economically for small, medium and, thanks to the fully automated production available at WEBER FIBERTECH, also for large series.

Low-stress processing

Less distortion of components, increased temperature stability due to low tool pressures.

Production of large parts

Part production up to 2 m², economical production of medium-sized parts using family tools, for example.

Hybrid technologies

Plastic - metal connections with form-fit connection between plastic and metal. Plastic and metal forming in a one-shot process in one tool and one process step. Metal blanks made of steel or aluminum are inserted unprocessed into the tool.

Sustainable production

All parts are fully recyclable.

Wide range of function integrations

Many options for integrating a wide range of functions. Visible surfaces, fabric back injection, paintable, reproducible properties. Inserts such as bushes or hinges, visible surfaces or fabric back injection.

Our fiber technology applied:

Our applications