FRP brochure

Transforming ideas into solutions FAST REAL PARTS

OUR SERVICES• Rapid product development consultancy• Fast, accurate, cost-effective REAL parts• Wide range of materials and production methods• Design and optimisation for manufacture• Rapid tool design and tuning• One-off development prototypes• High precision medical assemblies• Large scale automotive and marine projects• Technology-independent with a focussed network of specialist partners• CAD and materials expertise• Full project management support

OUR QUALITY• ISO9001 for Quality Management since 2004• ISO13485 for Medical Devices since 2008• Quality Team with Background in GMP/GLP/GCP• PPAP (Production Part Approval Process)• ISIR and FAIR including Cpk reports for Process Capability• Full Protocol and Report Documentation• Werth Scope Check Multi-Sensor CMM Inspection Equipment• In-house metrology department• ISO13485 Lead Auditor• Partner audits on behalf of our customers• Fully Audited Supply Chain

COMPOSITESComposite parts require a rapid or CNC tool to form a combination of a supportmatrix and a reinforcement material. This, when combined, gives characteristicssuperior to the properties of the individual component materials. FAST REAL PARTS

Processes Materials• Carbon Fibre – bagged, unbagged, • Thermosetting plastics eg. epoxy and pre-formed polyester resin, melamine and urea• Glass Reinforced Plastic (GRP) – hand lay formaldehyde and sprayed • Tufnol• Pultrusion • Ceramics/Glass/Kevlar• Insert moulding/casting • Laminate wood• Lamination Applications • Lightweight panels • Renewable energy • Large mould tools/marineProcess Time Material Quantity Application ExamplesComposite 3-4 weeks GRP/CNC/Ureol 1-5 Lightweight N/A tooling partsComposite 3-4 per week GRP/Carbon Fibre 1-100 Functional Car panels parts parts, cosmetic A-surface only Insert 2-4 weeks Polyurethane, 1-1000 Functional Seat base andmoulding/ epoxy resin with reinforced parts armrest reinforcement casting COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

MSUABNTRUAFCATCIVTEURINGSubtractive manufacturing uses the latest CNC and fabrication techniques tomanufacture parts using the production chosen material. FAST REAL PARTS

Processes5-axis CNC machining is ideal for precision engineered parts in a wide range of materials for avariety of industries. EDM is a machining operation using electrodes or wires that can generate fine detail andhigh precision.Laser cutting/water jet is suitable for profiling and subsequent fabrication.Process Time Material Quantity Application Examples CNC 1-2 weeks Metal 1000s(Metal) 1-2 weeks 1000s Functional Seat belt hook CNC 1-2 weeks (see below) 10s Parts 1-2 weeks Plastic 1000s(Plastic) 10s Functional Bush or CNC (see below) Parts bearing(Foam) Foam Laser Functional Seat pad (see below) PartsCutting Various Functional Vent Parts MetalEDM 1-2 weeks (see below) Functional Jewellery PartsMaterialsPlastics: ABS, Acetal, Acrylic, Nylon, PEEK, Polycarbonate, Polyester, Polyethylene, Polyimide, Polypropylene, PPS, PTFE, PVC, PVDF.Metal: Aluminium, Brass, Copper, Stainless Steel.Foam: PU, EPP, EPS. COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

CASTINGCasting uses a tool to form the shape of a component and is an economicmethod of manufacture when fewer components are needed. FAST REAL PARTS

ProcessesRIM Casting requires a more solid tool to pump PU resin into, producing parts in a fastturnaround time.Vacuum Casting uses softer silicone rubber tools where the PU resin is injected under a vacuumwith a cycle time of around 2 hours per shot (depending on size).Metal Casting – Die/Sand/Investment using traditional processes with the speed of additivemanufacturing.Process Time Material Quantity Application Examples PU Resin RIM 2-3 weeks, 100s Functional Interior trimCasting 20-30 parts Parts Low panels per day TempVacuum 2-3 weeks, 5-10 PU Resin 10s Functional HeadlampsCasting parts per day 1000s Parts Low Temp Metal 1-2 weeks All Metals Functional Bezels and sideCasting Parts strake COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

MINOJEUCLTIDOINNGInjection moulding is at the core of FRP’s business model as the process isflexible for both prototyping and production components. From the smallestmedical cleanroom parts to large automotive panels, we have a wealth ofexperience and expertise in providing validated parts with properties thatmeet your specific requirements. FAST REAL PARTS

Processes • Liquid Silicone Rubber (LSR) injection and • Rapid toolmaking in Steel or Aluminium compression methods• Choice of tool life – 5k, 50k, 100k, 1m+ • EPDM/rubber moulding including• Injection mouldings from presses synthetic fluoropolymers 10 - 5,000 tonnes• Twin-shot and overmoulding capability • Compounded and Masterbatch materials • Cleanroom moulding – ISO Class 7 and 8 available • Decorative finishes and in-mould decoration• Gas injection/EPP mouldings for lower Examples weight components • Regulated medical devices eg. inhalers, • Mould tool texturing and laser-etching injection devicesTypical Materials • Car bumpers and interior panels• Full range of thermoplastic materials • Metal replacement under bonnet parts available, including high percentage glass eg. inlet manifold and mineral filled and metal replacement • Technical mouldings eg. printer parts and glass replacement polymers Process Time Material Quantity Examples Toolmaking - 2-3 weeks Steel cold Up to 100k Low volumesmall-medium 3-5 weeks runner tools manufacture andToolmaking – prototype toolinglarge/technical Steel hot Up to 1 million High volume runner tools production tooling 1-2 weeks From low Small assembliesMouldings All volume to 1 million+ COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

FORMINGForming is a type of manufacturing which encompasses conventional processesto make a component or assembly of components. FAST REAL PARTS

Processes Materials• Metal Fabrication • Sheet plastics• CNC pressing and hammerforming • Mild steel/aluminium/stainless• Vac Forming • Heat resistant/multi-layer composites• Welding – Laser, MIG, TIG, cold and Applications ultrasonic welding • Low volume crash test parts• Bonding using latest dispensing methods • Brackets and materials • Under bonnet parts• Parts can be painted and powder • Heatshields coated/E-coated • Interior trims for leather wrapping• Parts can have a pinseal finish/grain finish Process Time Material Quantity Application Examples Metal 1-2 weeks Metals 1-1000 Functional Brackets 2-3 weeks Metals 1-100 Heatshields Fabrication 2-4 weeks ABS/PC 1-1000 parts, Interior trimCNC pressing 2-3 days Metals and 1-1000 non-cosmetic Build supportand hammer- plastics Functional parts forming parts,Vac Forming non-cosmetic Welding Functional parts, non-cosmetic Functional parts, non-cosmetic COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

AMDADNITUIVFEACTURINGAdditive manufacturing models are made from layers of material and aresuitable for appearance and prototyping as well as some productionrequirements. FAST REAL PARTS

Popular ProcessesSLA (Stereolithography) models are the ideal solution for show-and-tell parts. With a smoothfinish, fine detail and a quick turnaround time, this service is ideal for visual prototypes.SLS (Selective Laser Sintering) models can be used in every stage of the development cycle,from one-offs to functional tests to small production series. FDM (Fused Deposition Modelling) uses a process similar to hot glue gun extrusion in a rangeof production-representative materials, providing small series and functional model parts.Other ProcessesThere are many other machines based on the above technologies that offer specialist resultssuch as rubbers, waxes, colours and fine resolution, all of which we can offer to meet yourspecific requirement.Process Time Material Quantity Application Examples SLA 2-5 days Photopolymer 1-2 SLS 3-5 days 1-2 Static show Paint finish FDM 2-5 days ABS-like 1-2 part trim parts Nylon Functional part Leather- Functional part wrapped ABS/Nylon/PC substrate Leather- wrapped substrate COST QUALITY QUALITY SPEED (NO (HAND REPRESENTATIVE FINISHING) FINISHING)HIGHMEDIUMLOW

FAST REAL PARTS Fenland RP Ltd, Units 4 & 5 Evergreen Venture Park Barton Road, Wisbech Cambridgeshire, PE13 4TP Tel: +44 1945 411700 Fax: +44 1945 411701 Email: [email protected] Web: www.fenlandrp.co.uk