WICKERT will be presenting a complete RTM door inner core for the Airbus A 350 at this year's Composites Europe 2013. The highly stressable (carbon) fiber composite component is manufactured in a Resin Transfer Molding (RTM) process at Eurocopter in Donauwörth, Germany.

This procedure makes it possible to produce structural components with comparatively high fiber volume content and good impact properties, while slimming down on weight at the same time.

This case involves an injection process that uses the WICKERT WKP 2500 S Composite Press. The WKP 2500 S Composite Press is based on the proven modular system found in WICKERT downstroke presses. Because the carbon parts are never permitted to be exposed to even a hint of oil mist, the hydraulic press system was required to be absolutely oil-tight.

This was achieved by completely enclosing the press area and the entire press technology peripheral system, including the hydraulic and electric systems. The press, which has a closing pressure of 2500 kN, features an upper and a lower mold, each permanently installed.

The clamping plates measure 2400 x 1800 mm. The control and process visualization integrates the injector, heating/cooling system and press shuttle. The latter handles the fully automatic fitting with the center mould, which is fed from high-bay storage, and also the return transport after the process. The cycle time is around 6 h per airplane door.

As is customary in the aerospace industry, comprehensive data acquisition and detailed documentation of the manufacturing process, including tracking through all operator actions, are included. With this demanding manufacturing assignment, WICKERT once again demonstrates that hydraulic presses can meet the most demanding requirements.