Until recently, the application of thermoplastic composites was a costly matter. With the introduction of FALKO technologies, that concern is a thing of the past. FALKO transforms UD tape into semi-finished products suitable for any pre-existing consolidation processes. The result is both lightweight and extremely durable, and can be moulded into a wide variety of premium products and components. FALKO makes the production process of UD tape easier, more reliable and cost-efficient.
FALKO has been developed through years of research and experimentation with a variety of technologies. Eventually, we decided on a combination of slitting, automated tape laying (ATL) and automated fibre placement (AFP) techniques with ultrasound. Through this process, UD tapes are cut into smaller strips and subsequently welded together without interruption (continuously). A unique and ground-breaking innovation.
Various technologies are combined in order to guarantee the highest quality laminates. Through slitting, any faults and imperfections in the UD tape are removed and prepared for tape laying. Advanced CAD/CAM software decides on the optimal placement strategy. A real-time gap and laminates verification system, verifies the position of every individual UD tape during the production process. The highly efficient ultrasonic welding technology improves the reliability of the process and therefore guarantees the quality of the final product.
Cost-efficiency is another advantage of the applied technologies. When it comes to the valuable materials, there is barely any spillage. Outages are reduced to a minimum as well, thanks to the real-time gap verification system. The ultrasonic welding technology reduces the processing time and enables reparation and corrective measures during production. With a production capacity of up to 450 m2 per hour (depending on the material and the configuration), FALKO is ready to mass manufacture your thermoplastic composite components, recouping your investment costs in no time.
The FALKO produces large-scale and complex thermoplastic composite laminates and near-net-shape products at a superior quality. Compared to traditional methods, it is extremely light weight yet exceptionally strong, impact-resistant and not subject to corrosion. In addition, the material is weldable, leading to a stark reduction in costs. The absence of rivet holes means the construction becomes more durable too. All these properties make for significant advantages and new opportunities.
Working with FALKO thermoplastic composites means a never-ending flow of possibilities. The material is not only used to create lightweight components for cars and aircrafts, but also has its place in the production of next-generation wind turbine blades, hockey sticks and tennis rackets. What opportunity does FALKO offer your organisation?
FALKO introduces new materials and technologies to offer you new opportunities for development. We do our work with the world of tomorrow in mind. With FALKO, processing thermoplastic composites becomes energy-efficient and highly sustainable through the use of 100% recyclable materials, resulting in a lower carbon footprint for your product. In addition, a lighter aircraft or vehicle uses less fuel and has a lower CO2 emission. The products of the future, produced today by FALKO.