High-tech production solutions from the initial idea to series production

FRIMO Innovative Technologies were presenting highlights from its comprehensive technology portfolio at JEC World, which took place in Paris from March 4 to 6 2025. Efficiency, flexibility and individuality are at the forefront of the development and implementation of production systems for processing composites. This includes innovations from NFPP and organo sheet processing, preforming, RTM, compression and wet compression molding, with which FRIMO brings ideas for lightweight construction and structural components into series production, e.g. complete roof modules or underbodies for automobiles, battery housings or shielding through to sandwich panels for the construction industry, components made of ballistic composites or even natural fiber components with new surfaces.

PU processing also offers high potential, with machines and tools for flexible, semi-rigid, rigid and integral foams as well as filled PU systems, and the entire tool technology, ergonomic, electrically driven mold carriers, stationary and mobile systems as well as mixing and dosing technology. FlexTrim trimming solutions in the form of precise ultrasonic cutting and milling as well as surface activation and adhesive application complete the portfolio for plastics and composites processing. The individually configurable systems guarantee maximum efficiency and quality. Plastics joining with modular FlexLines for ultrasonic welding, heat contact riveting, gluing and screwing can be adapted and expanded in many ways for flexible production, also as a supplement, SemiFlexLines, in existing systems to increase productivity.

The holistic solution approach also includes the implementation of all upstream, intermediate and downstream process steps. Together with its customers, FRIMO finds the right solution for newly developed materials and product ideas - from the early development phase through to series production and after-sales service.

Automized Wet Compression Molding for shorter cycle times and higher productivity
Compared to RTM, wet compression molding can be carried out with lower process pressures. This means that fiber composite structures can also be combined with sandwich cores, for example made from foamed polyurethane or polyethylene cores, or paper honeycombs in a single work step during the compression molding process. The tool technologies that can be used enable economically interesting concepts combined with significant savings in cycle time. Another advantage compared to RTM is that the additional process step of three-dimensional preforming of the semi-finished fiber products can be omitted.

For the production of fiber-reinforced structural components, e.g. complete roof modules or other assemblies, FRIMO Innovative Technologies offers fully automated systems for the wet pressing of monolithic and sandwich components. In this process, dry continuous fiber fabrics are impregnated with a reactive resin outside the press, then transported into the press and consolidated there, where the matrix materials then harden.

Hybrid Solutions through combination of Plastics Injection Molding with Metal Die Casting
As a technology partner in the HyDrun research project, FRIMO Innovative Technologies played a leading role in a new development that succeeded in combining two different processes, such as metal die casting and plastic injection molding, in a single system technology in one process. This should enable hybrid material composites to be produced in a single step and without additional process steps.

In November 2024, the final event for the HyDrun project took place with a technology show at the LEIV (National Lightweight Validation Center) in Dresden. In front of the project partners and numerous invited guests from industry and science, hybrid gearbox housings were manufactured on a machine from project partner company DSD. Initial discussions on potential follow-up projects were held during the event.

Recyclable Multi-Material-Design for Lightweiht Structures (MM4R)
A hybrid design of lightweight vehicle structures, which uses a minimal variety of materials with maximum design freedom and enables contamination-free recycling and reuse of recyclable materials, can make a significant contribution to reducing the environmental impact. A holistic sustainability assessment (LCSA) and integration of the SDGs support the political objectives of industrial and innovation policy.

As part of the MM4R project, FRIMO will develop, manufacture and commission a near-series injection molding tool. Within this framework, the requirements, functions and the specification of the overall process are defined together with the project partners in order to drive forward the tool and process development. Finally, the finished tool will be installed in an overall process chain close to series production in order to manufacture the demonstrator components. The project objectives in terms of energy efficiency and resource-saving potential are a main focus during tool development. For example, the processing of recycled materials is planned, as well as options for the reduction of sprue waste.

NFPP with demanding Surfaces – Innovative, versatile and functional
JEC visitors could find out from FRIMO about the possible applications of NFPP in a new dimension and quality. The solution developed together with KURZ supports the implementation of sustainable and at the same time aesthetically extremely demanding sophisticated interior concepts. The process makes it possible to impressively showcase natural fibers such as flax or kenaf with their characteristic appearance. The natural design language of the material is emphasized and the structure of the natural fiber becomes a visual highlight thanks to the special processing - an innovative product with numerous application possibilities.

This new solution can be combined with established process technology. A decorative layer in the form of a PP-based KURZ decorative film is applied to the natural fiber PP mat in the first step, and then pressed by means of pressure and heat. In this way, the PP decorative film and the PP fibers contained in the mat are fused together plastically. The pressing pressure and the compression of the mat causes the non-plastic natural fibers to move to the interfaces of the NFPP mat, thus be covered with the decor or design. In the second step, the component is given its final shape in a second forming tool.

The use of natural fiber PP composites offers improved material properties combined with great design freedom, i.e. a wide range of advantages that are of interest for interior solutions in the automotive segment, but also for many everyday products where lightweight, yet stable and decorative covers are required. The visual integration of natural materials, combined with a tactile and individual feel, creates a new understanding of design and opens up a wide range of design options. Among other things, the intelligent integration of functional elements and reinforcements is also possible. At the same time, the components impress with their high strength and rigidity and exhibit good crash behavior. Due to their low density, they are also around 25 to 40 percent lighter than pure plastic components. They also offer excellent insulating properties, which leads to energy savings and sound optimization in the interior.

Holistic Approach for Efficiency, Flexibility and Individuality
Lightweight solutions from FRIMO Innovative Technologies offer project-specific benefits such as a reduction in CO2 emissions, improved energy efficiency, material savings, simplified application or production processes, functional integration, bundling of technologies and minimizing of production cycles and assembly times. The comprehensive spectrum of technology and know-how enables process-neutral consulting. This means that technically and economically adapted solutions can be implemented - with tools, machines and systems from a single source, including customized automation and subsequent after-sales service.