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Lightweighting Your World.

Rapid

Efficient

Layup

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Fiber reinforced thermoplastics are

the future of structural composites.

Thermoplastics offer excellent

toughness, stiffness, impact

attenuation, chemical resistance

and flammability performance.

High material and processing costshave prohibited the adoption of

thermoplastic composites for volume

applications. Enter Fiberforge. With

Fiberforge, advanced composites in

high volume production applications

are an economic reality.

Fiberforges RELAY Station is an

automated thermoplastic tape

layup system. RELAY stands for

rapid, efficient layup, and both

the equipment and the process are

protected by patents.

Fiberforge designs and produces

its RELAY Station equipment and

sells to manufacturers, worldwide to

make strong, lightweight and cost-

effective parts.

Fiberforge partners with other

equipment suppliers and system

integrators to offer complete

manufacturing solutions.

Fiberforge RELAYStation

Breakthrough technology for the rapid

production of advanced composite parts

Rapid lay-up of tailored blank

by RELAY Station: minute one

Consolidate blank: minute two

Thermoform blank: minute three

Fiberforge technology:

Extremely high

throughput

processes over 200 lbs.

(90kg) of material per hour

Automated

Accurate, repeatable

and reliable

Intuitive, easy-to-use

interface

Unsurpassed design and

engineering support

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Fiberforges patented RELAY Station is a state-of-the-art

tool for the rapid, high volume production of fiber-reinforced

thermoplastic composite structures.

Process Summary

The RELAY Station includes a rapid

tape dispensing system, which feeds

composite tape through a track

positioned above a two-axis motiontable. Based on the specifications

of the part being produced, tape

lengths are fed into the track, cut,

and placed on the table. As the tape

is placed, a series of ultrasonic weld

tips descend and rapidly tack the

tape to the ply beneath it.

Following welding, the table

indexes to a new position to lay the

next course. This process repeats

until a multi-ply tailored blank is

constructed. Following lay up, the

blank is removed, then consolidated

and thermoformed into a 3D part.

Fiberforges proprietary software,

TailorGen, generates the tailored

blank design from a 2D model and

feeds the design to the RELAY Station

for production.

RELAY Station

Operating System Specs PC-Based Operating System 9 Servo Axes

Windows-based operatingplatform

Touch screen, full manualand auto control

Advanced error indicatorsand data logging

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RELAY 1000 Series 2000 Series

Max. Blank Size 1m (40") x 1m (40") 2m (79") x 2m (79")

Footprint 5.7m (18.7') x 5.5m (18') 7m (23') x 9.6m (31.5')

Maximum Throughput* 230 lb./hr. 368 lb./hr.

Tape Width Range 50 mm (2") - 150 mm (6") 50 mm (2") - 150 mm (6")

Tack System 10 weld heads 18 weld heads(with power supply and sequencer)

Vacuum Table 2 zones 8 zones

*Actual throughput may vary based on tape width, part design, material type and machine options.

Fiberforge RELAYStation

RELAY Station Specifications

System Specifications and Upgrade Options

FiberforgeCorporation

1420 Devereux Road

Glenwood Springs, Colorado

81601 USA

phone +1.877.945.9377 | +1.970.945.9377

FiberforgeGmbH

Mattweg 3, CH-6340 Baar, Switzerland

phone +41 (0) 44.58.66.77

info@fiberforge.com Fiberforges technology is protected byU.S. patents 6 ,607,626; 6,939,423; 7,235,149; 8,007,894;8,048,253 and patents pending. 2012, Fiberfo rge Corporati on. FFRS1212V6

fiberforge.com

Standard Option

Resolution C = 0.01

Y = 0.025 mm (0.001")

U = 0.1 mm (0.004")

Repeatability C = 0.05

Y = 0.2 mm (0.008")

U = 2.0 mm (0.080")

Minimum Course Length 86 mm (3.4")

Tape Width Tolerance 0.4 mm (0.016")

Tape Thickness Range 0.1 mm (0.004") - 0.4 mm (0.016")

Graphic User Interface Windows-based touch screen

Part Logging Textfile SQL database connectivit y

Warranty 1 year 3 or 5 years

Weld Method Simultaneous Simultaneous

Creel System Double creel

Tape Loading Manual Automatic

Part Removal Manual Automatic

Carriage Tray Auto adjust