Competence in lightweight construction
From the initial idea, through conception and development, to series production – everything from a single source.
Weber Fibertech is an expert in the production and development of long fiber reinforced thermoplastic parts. For more than 25 years, we have been developing and manufacturing very lightweight components with high strength, maximum stiffness and excellent mechanical properties. Our customers are well-known companies from the automotive, mechanical engineering, construction and agricultural industries, among others. We know our way around here and have mastered the high technical requirements and quality demands for many years. Trust in our expertise and let us implement your next bike project together, from feasibility study to large-scale production.
Your product is too heavy? You have supply problems, but have always sourced the metal component this way?
The total costs incl. scrap, rework, logistics seem too high to you? Sustainability is becoming more and more of a focus? Recycling concepts and return of the material! Your desired design cannot be realised? Innovative integrations are only possible at considerable extra expense?
Let us work together to develop the idea of how we can design a product that will bring you significant advantages in all of the points mentioned.
You are not familiar with plastics technology for such complex components? Weber Fibertech has more than 25 years of experience in the substitution of metal components into lightweight, cost-effective thermoplastic components.
We will implement your idea together with our know-how!
First conception & design
The idea is born, the first design is ready. We create an initial concept for your component, determine a target weight, lay out an initial manufacturing idea. We advise you on the many hardly limited design possibilities of our technologies, give you advice for a good plastic-compatible design of your component and the simplification of the concept based on the possibilities offered by our technologies. We look in detail at the economic aspects and give you an overall cost overview. In addition, you will receive a detailed schedule for your internal time planning. Our goal is to provide you with the best basis for decision-making.
Plastics technology for your component is a new step for you. Would you like even more detailed investigations of your idea? Does the component also meet your special requirements, is this really feasible in plastic? No problem! We offer you a comprehensive basis for decision-making, from the initial assessment to a detailed feasibility study - both from a technical and, of course, an economic point of view.
After a positive concept and feasibility study, our experienced project team will draw up a detailed project plan for you, including scheduling, always focusing on your wishes and milestones. For extensive projects, we use APQP or VDA processes, depending on the customer's wishes, in order to monitor the achievement of objectives in all areas and to carry out fine adjustments and optimisations if necessary. With this comprehensive and detailed project management, we ensure that your project is implemented successfully and on schedule - from the initial idea to series production.
Based on your requirements, we create an optimal production concept for your product. The focus is always on an efficient lightweight construction that can be produced economically. Weber Fibertech Multi-Technology: by selecting the right manufacturing technology for your product, we are able to select the technology that best suits your requirements and offers the best balance between lightweight construction and economic efficiency.
The concept phase is followed by the construction of the CAD model. Various software programmes and powerful hardware are available for this purpose. Our engineers can build the models in shell as well as in solid design according to your requirements. Once the model is complete, drawings are made to define connection points and contact surfaces to neighbouring components by tolerance. Our development engineers also always keep an eye on the plastic-compatible design - this leads to process-stable production in short cycle times.
Parallel to the component design, the process- and load-appropriate selection of the material takes place. This is one of the strengths of our technologies. There is an almost infinite choice of material configurations available, both for the polymer and the reinforcing fibres.
FEM structure simulation
After design and material selection, extensive calculations and numerical simulations are carried out according to the finite element method (FEM), which ensure an optimal design of the component in the load case.
We optimise the topology of the component with regard to possible load cases: at non-critical points, we reduce wall thicknesses and material accumulations to the required level. Stressed areas, on the other hand, we reinforce with continuous fibres (glass or carbon) or even with a structurally reinforcing hollow channel - or a combination of all of these, depending on the load case. The optimisation of the structure is a decisive factor for the successful and economical implementation of your component.
Through simulation, we ensure that the resulting component withstands the loads and meets all requirements and specifications. Both static and quasi-static load cases can be mapped, as well as dynamic ones that simulate a crash, for example.
Using FEM simulation, we safeguard the most diverse load cases so that your component can withstand the expected loads with the lowest possible weight.
We use process simulations to simulate the filling process of the injection mould in order to identify problem areas at an early stage. By taking specific measures on the component or mould design, we ensure that faults such as weld lines and air inclusions are avoided and that production can take place in the shortest possible cycle time.
Furthermore, simulation enables us to detect potential component distortion at an early stage and to take specific measures to remedy the situation.
The filling simulation also provides information on the subsequent fibre orientation in the component, which is the basis for an anisotropic structure simulation. If one is able to influence the fibre orientation in a targeted manner, the component can be designed absolutely in line with the load path, which ultimately leads to a lighter and more cost-efficient result.
Production & Quality Planning
We carry out detailed production planning in parallel with component development. The aim is always to make the best use of resources, to design the process effectively without non-productive time and to realise absolutely process-stable production in the entire manufacturing plant. Quality does not begin with the production of components. Our advance quality planning starts as early as the component development stage. Critical characteristics and dimensions are defined here and we plan which methods we can use to guarantee 100% compliance with customer requirements. This also includes the design of measuring methods and gauge concepts.
Weber Fibertech has many years of know-how in different tool technologies. A good tool has its origin in a good component design. Our development engineers always keep this in mind during the development of the component. With our know-how, the plastic-compatible design of the component and in close cooperation with renowned toolmaking companies, we create the series tools. In this constellation, we guarantee short production times, a smooth start-up of new tools with minimal optimisation effort and reliable, process-stable tools over the entire production life.
Prototypes & sample production
For the first parts, we produce prototype and sample parts according to your wishes in cooperation with renowned sample manufacturers.
We offer the complete range of samples, from 3D printed illustrative or construction samples to near-series components that can also be subjected to load tests.
Based on the preceding quality planning, we carry out comprehensive testing of your components: in-process tests, 3D measurements, various material tests, climate change tests, sunlight simulations, climate temperature storage and outdoor weathering.
With our manufacturing process, we can produce both small and medium quantities economically. At the same time, our fully automated production also enables us to produce large series economically.
On the one hand, our production system enables us to continuously monitor the quality of the production process. The processes are continuously checked digitally to ensure that there are no process fluctuations that could have a negative impact on product quality. In addition, all processes and materials of the produced component are digitally stored. Each component is given a consecutive identification number or QR code. This means that it is always possible to trace under which conditions and with which material batch and process parameters the component was produced - even after years. A part tracking system for your benefit and safety. And when the component comes back to us for recycling, the identification number immediately gives us detailed information about the production process of the component.