TECHNOLOGY IN CARBON MANUFACTURING
Each day at G&G Compositi we work in a close and constant relationship with technology. The continuous evolution of materials and equipment enables us to always be in the forefront not only in production but also, and above all, in offering our customers innovative solutions, consistent with the project being developed and with process optimization. This is why Research and Development have always been essential in the evolution and continuous growth that our company has experienced in the many years of passion we have punt into our work.
The success of any project greatly depends on the initial analysis and feasibility study phase. Together with the customer, we verify the geometry of each single component with the aim of making available all our experience and know-how so as to check and improve the characteristics of the part. It is here that the complex production process begins, starting with rendering and then on to the 3-D prototyping, which is done entirely in house at G&G Compositi, along with all the other stages of production.
The file with all the numbers is sent from the G&G Compositi design department directly to the Nibbia plant, where the Bellotti 5-axis workstation begins to prepare the model, starting from a solid block of material. The block is then milled into shape to become the model from which the mold will be obtained.
Making the mold in house is something that G&G Compositi has never wanted to give up. This choice means having direct and constant control over one of the essential elements for quality production.
Following the design phase, the next step is the cutting room, where a computerized cutting plotter cuts out the carbon fabric skins used to make the part. The only time in which this is done manually is when a cut for a particular component is required.
An area measuring over than 70 m2 houses the clean rooms. These environments are climate controlled at a constant temperature of 20°C and rigorously monitored and sanitized to avoid contamination of the carbon fibers during this processing phase. The experience and manual skills of the workers involved in this stage are essential because it is here that the skins are meticulously laid into the molds according to the ply book, i.e. the manual containing the details for laying out the fiber weaves and obtaining maximum resistance while remaining within the weight range specified in the design.
OVENS AND AUTOCLAVES
This is the material baking and stabilizing phase which, under special pressure and temperature conditions, changes its structure thus acquiring the high level of rigidity typical of carbon. The highly advanced equipment used is no doubt one of the keys to the success and growth of G&G Compositi. However, in this stage as well, human intervention makes it possible to better optimize bag sealing so all parts adhere perfectly.
- 1 Maroso autoclave measuring 1000X2000 with 7 vacuum attachments and equipped with cycle control disk
- 1 Maroso autoclave measuring 1200X3000 with 10 vacuum attachments and equipped with cycle control disk
- 1 oven measuring 3000×3500, max temperature 140°, equipped with vacuum pump
- 1 oven measuring 1000×1000’ max temperature 180°
Once it is removed from the mold, the part is sent to another department where it undergoes a very delicate process: finishing. At this time the quality of each part is carefully inspected before proceeding to the delicate manual finishing phase in preparation for final painting (the only process that is done externally). During finishing, in addition to product enhancement, all the gluing and assembly operations of particularly complex parts are carried out in a dedicated department.
Quality control is performed various times throughout the entire production cycle. In the last stage, the product goes through a final inspection to ensure that all its parameters and characteristics comply with all the strict weight and finishing specifications. Once the inspection is passed, each part is ISO 9001 certified and prepared for delivery.
CNC MACHINE SHOP
The entire facility of Nibbia has been designed and built to further expand G&G Compositi, thus launching the phase of special production for in-house use as well manufacturing to order. To achieve this objective, the fleet of machines has grown to include a new and ultra-modern Bellotti 5-axis workstation, which will make it possible to expand and further speed up the company’s processing capacity.