Winding technology

For rotationally symmetrical components – high mechanical properties, economical and scalable.

Filament wound components from Connova Group differ from conventional components due to their extremely good mechanical properties, attractive component costs and their high, process-reliable scalability for large-scale production. Connova Group’s filament winding technology enables a perfect laminate that conforms to the force flow and allows a wide range of component geometries. A very lightweight design with maximum strength and rigidity makes them ideal for highly stressed components where a long service life is required.

The continuous glass or carbon fibres are mechanically impregnated in a resin bath and placed on a rotating tool mandrel by CNC-controlled machines. The fully automated manufacturing process guarantees absolute reproducibility and the highest quality of series components. In addition, the winding technology, also known as filament winding, is extremely interesting from an economic point of view due to the high degree of automation and therefore low contract manufacturing costs and, in contrast to conventional fibre composite processes, there is virtually no wastage. Filament winding technology is primarily suitable for the production of rotationally symmetrical components such as tubes, shafts, beams or containers.

The strengths of the wrapping technique:

Perfectly definable fibre placement
Optimised mechanical properties
Ideal fibre content
Low pore content
Lower weight
Lower inertia
High rigidity
Very good vibration damping
Very low thermal expansion

Compared to CFRP components made from woven fabrics, wound components weigh 20% less and achieve the same mechanical properties. The process is characterised by high precision and good reproducibility. The processes can be largely automated and produce highly economical, reproducible components, even in small batches.

The wrapping technique is used:

In e-mobility: rotor drums, slit tubes
In automotive engineering: compression struts, test bench actuators, tensioning straps
In aviation: props, camera supports
In mechanical engineering: tool extensions, laser guide tubes, rollers, pressure tank bandage
In robotics: actuators
In water treatment: pressure pipes, filter bodies

The Connova Group has the expertise and resources for winding technology:

Multi-spindle CNC winding machines, each with four freely programmable axes
Maximum winding length of up to six metres
Largest diameter 600 millimetres
Maximum weight per component 1,500 kg
CNC process software and simulation of the winding with “COMPOSICAD”
Computer-controlled and automated curing ovens

Winding machine

Eine Wickelmaschine besteht aus einer Drehvorrichtung für den Werkzeugdorn, Fadenführung und Fadenspeicher sowie einem Harzbad, das sich entlang der Drehachse hin und her bewegt. Mit einer revolutionäre Wickelmaschine des Deutschen Weltmarktführer „Roth Industrie“ bietet die Connova Group eine stabile und ausfallsichere Bauteilversorgung vor allem auch für Grossserie Fertigung von 10.000-100.000 Bauteilen pro Jahr. Durch das neuartige Prozessdaten-Überwachungssystem wird ein ausgezeichnetes Prozessfähigkeitslevel erreicht, sodass neue Märkte und Anwendungen angegangen werden können, die bisher mittels Wickeltechnik nicht erschlossen werden konnten.

Further competences