Porsche-Heckflügel aus Carbon

Our Prozess

HOW WE DESIGN HIGH-STRENGTH LIGHTWEIGHT COMPONENTS

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CAD-Modell eines Kleinstwagens

construction

First, we design the component or part group according to your requirements in CAD (CATIA V5, Siemens NX), ensuring that the design is optimal and compatible with fiber composites.

Verformungsanalyse eines Führerhauses

Layout

Using programs developed specifically for fiber composites, we calculate the static and dynamic properties of your component using the finite element method, optimising function, weight and costs.

CAD-Modell einer Fertigungsanlage für Carbonteile

PLANT AND TOOL CONSTRUCTION

We design the tools ourselves so that your CFRP parts meet the highest standards. In addition, we even develop some of our preform and RTM systems, including presses, ourselves to implement unique processes and technologies for you.

Prototypenherstellung eines Crbonteils

PROTOTYPING

We have a variety of methods with which we can produce prototypes. As a result, they are quickly available, have the same component layouts as series parts and are cost-effective.

Carbonteile in einer Lager-Halterung

SERIES PRODUCTION

With 30 presses, 3 CNC cutter systems, 5 CNC milling machines, 6 tempering furnaces and the competence to design new systems ourselves, we produce everything from large to small series. We manufacture SMC processes using RTM, wet and prepreg presses and carbon fiber.

Our advantage: RTM

Semi-finished products

Eine illustrierte Rolle Carbonfasermatten

First, semi-finished products are cut from fiber mats or embroidered from fibers, or woven.

Laying the semi-finished products

Eine Illustration, die mehrere Carbon-Fasermatten zeigt, die aufeinandergelegt werden

The cut fiber mats are placed on top of each other until they have the desired thickness.

Preforming

Eine Preform-Presse für CFK

Using heat and a binder, the mats are pressed into the three-dimensional shape of the component in a press.

Cut the preform

Eine Illustration, die eine ungetrimmte CFK-Preform zeigt

Excess fiber material at the edge of the preform is trimmed away. The preform is taking shape.

Combining dry preforms

Eine Illustration, die das Aufeinanderlegen mehrerer CFK-Preforms zeigt

The preform layers are combined together and are now ready for the RTM press

Close the RTM press around the preform

Eine sich schließende RTM-Presse

The specially manufactured RTM press now closes tightly around the preform part.

resin injection

Eine RTM-Presse, in die Harz injiziert wird

Resin is injected into the press together with a catalyst and impregnates, hardens and encloses the mats.

post-processing

Eine Illustration die das Polieren eines CFK-Teils zeigt

The hardened component can be post-processed (sanding, polishing, coating, painting, etc.)

Finished component

Illustration eines fertigen Carbon-Bauteils

The component is now complete. Thanks to the RTM process, it is economical to manufacture, lightweight, stable and has a high surface quality.

Our production

GT4RS Kotflügel in der Fertigung

preforms

Carbonfaser RTM-Presse

RTM (RESIN TRANSFER MOLDING)

CNC-Router fräst an einem Audi R8 Mitteltunnel

CNC MACHINING

Ein ACE-Mitarbeiter verklebt ein Bauteil

ADHESIVE MOUNTING

Nahaufnahme eines Carbonbauteils

FINISH

Posche 911 Kotflügel in der Qualitätssicherung

QUALITY CONTROL

ACE is also a system-
supplier

Audi R8-Spyder-Motorhaube und VerdeckkastenabdeckungAudi R8-Spyder-Motorhaube und Verdeckkastenabdeckung

Painted soft top box lid

Engine flap

Grill inserts

Visible carbon slats

1

2

3

4

The engine flap and tailgate cover of the Audi R8 Spyder, developed by us as a part system/assembly.

1

Painted soft top box lid

2

Visible carbon slats

3

Grill inserts

4

engine flap

ASSEMBLY, PAINTING, DELIVERY

We don't just produce fiber composite parts:
At ACE, we also offer the assembly of the parts, as well as the combination with other components (e.g. injection-molded and metal parts) and their painting and delivery.
Our production adapts to your concept, with the direct delivery of finished components on a just-in-time basis, in the correct installation order. This gives them time, efficiency, and saves organizational effort.

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Our KNOW-HOW:
CFRP REPAIRS

ACE IS AN OFFICIAL CFRP REPAIR PARTNER OF*

Toyota/Lexus Logo
Lexus LFA von vorne

*for the Lexus LFA

WE KNOW HOW IT WORKS:

CFRP DAMAGE REPAIR

ACE is one of the few companies in the world that have the necessary know-how to successfully carry out complex repairs on structural carbon parts to a high standard.

CFK
REPAIR TRAINING/WORKSHOP

We share our knowledge: Since carbon is our passion, we offer repair training for CFRP parts, which enables companies all over the world to repair the material.