Composite Mouldings, Sandwich Panels & Components
Permali offers its customers a wide range of tailored composite solutions and composite components to suit specific needs, designed and manufactured under exacting AS9100 accredited quality standards.
We offer semi-finished fibre reinforced epoxy, phenolic and UHMWPE composite sheet materials, in sheet sizes up to 8.7 sq.m.
Our production combined with technical expertise in formulating composite resin systems using specialty fillers and additives, along with design engineering and materials testing capabilities makes us experts in composite solutions
Composite Solutions
Finished composite components
Glass and aramid fibre reinforced prepregs and solid or sandwich design laminate sheet materials are supplied as semi-finished products to convertors. Lightweight ballistic grade sheet materials are also high pressure laminated from specialist UHMWPE fibre products for armour plate applications, such as DSM Dyneema® and Spectra Shield® from Honeywell International Inc.
Alternatively, finished composite components are manufactured to order, either CNC machined from in-house produced composite sheet materials or closed moulded. Depending on individual customer requirements, Permali can also supply sub-assembly composite parts with metal fixtures, or fully assembled finished components, painted or with special PU coatings, ready to fit.
Composite Component Production Capabilities Overview
Permali’s extensive in-house production capabilities for manufacturing composite solutions include:
Prepreg production
Prepreg production of glass fibre, aramid and other fibre reinforced epoxy or phenolic materials, on a roll or as cut to size sheets.
High pressure laminating
High pressure laminating of epoxy, phenolic and UHMWPE composite sheet materials
Hot pressing
Hot pressing lightweight ‘sandwich’ design composite sheeting, combining balsa, Plasticell® PVC foam or other closed cell foam cores with in-house laminated sheet materials for the two outer skins.
Compression moulding
Compression moulding solid FRP laminate sheeting from epoxy and phenolic liquid resin systems or from UHMWPE and continuous fibre reinforced thermoplastic materials.
Closed moulding
Closed moulding (vacuum bagging & liquid resin infusion – RTM / RTM light/ VARTM) of complex shaped FRP composite parts based on epoxy, VE or phenolic resin grades custom formulated with mineral fillers and additives to meet fire and other regulatory standards.
Sub assembly
Sub assembly of CNC components, precision machined from Permali manufactured composite sheet materials or closed moulded parts.
Fully finished, assembled, coated/painted CNC machined and closed moulded
Fully finished, assembled, coated/painted CNC machined and closed moulded composite components.
Key Composite Products & Market Applications
Permali has established market leading positions in a number of key markets and application areas with its innovative composite solutions:
Armour & Spall Liner systems
Appliqué armour, ballistic and blast protection composite materials for land vehicles, fixed and rotary wing aircraft and marine vessels used by the Defence industry (Army/ Navy/ Airforce), security forces and for VIPs.
Fire Resistant
Fire resistant cargo bay liner systems & maintenance ‘peel and stick’ repair patches for commercial aircraft.
CCHS®
Permali’s proprietary cargo handling system for the CH-47 Chinook helicopters, designed for the rapid despatch of wooden cargo pallets. The system is fully compatible with Permali’s armour upgrade lightweight ballistic protection system for the helicopter’s cockpit and cabin areas, which can be retrofitted.
FRP composite stanchions
MOD approved non-conductive, corrosion resistant high strength FRP composite stanchions for manual and automated flight deck net systems and guard rails on aircraft carriers and other naval fighting ships.
Underfloor protection
Underside safety shield for racing cars, to protect against high impact debris damage to vital under chassis areas; anti-blast under floor land mine protection for military vehicles in operational service.
FST
Fire, smoke and toxic fume (FST) rail sector rated electrical insulation and crash impact energy absorbing glass fibre reinforced composite laminated sheet materials used for manufacturing rolling stock components.
Composite Material Grades
Permaglass 22FER28 Technical Datasheet download – if you are looking for one in particular that is not available, please get in touch with our experts.
When moulding composites, a wide breadth of processes are used to create the desired finish, all of which require precision controls
Permali’s Composite Moulding Processes:
Wet Lay
Wet lay can be used for heavily filled resin systems. Permali uses DSM Synolite polyester resin for simple composite mouldings, which provide good electrical resistance and outstanding flammability performance.
Open Moulding and Vacuum Bag Bonding
Creating a highly compact composite finish, vacuum bag moulding creates strong layered products where two or more fibre layers are bonded with a resin product. This method also ensures no excess resin is wasted as the vacuum creates excellent consolidation resulting in low voidage and excellent adhesion.
Closed Moulding
One of our specialities is utilising closed moulding techniques commonly referred to as RTM light (or vacuum-assisted resin transfer moulding (VARTM) for small to medium production volumes. For higher volumes, Permali have also used more conventional RTM moulding processes).
The obvious advantages of closed moulding include superior precision and repeatability. Considerations should also be given to a safer and cleaner working environment with less exposure to resins and fibres.
This includes notable improves, such as:
• Greater scope for automation
• Reduced manual labour
RTM Light (LRTM)
Where RTM will use a high pressure, LRTM normally uses a lower pressure. This allows for more flexibility in the types of resin, fillers and fibres used. LRTM is fast becoming industry preferred, and at Permali, we are proud to offer industry leading RTM Light. Popularity is growing with RTM Light because of the low tooling costs, leading to short lead times for customers.
Resin Transfer Moulding (RTM)
RTM uses pressurised environments to create fast cycles and product consistency by injecting resin into a mould already containing the fibres required. It allows a broad range of tooling in either hard or soft form. Permali can achieve fast cycle times due to heat-controlled mouldings, enabling swift turnaround for time-sensitive products.
Compression Moulding
With fast curing times that last no more than five minutes, compression moulding involves putting the ‘charge’ of moulding material into the mould, where it can be heated up to over 200°C and pressed in a high-pressure cavity.