Heavy Truck Panel RIM/LFI Solution Banner background

Heavy Truck Panel RIM/LFI Solution

Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces.

Submit Production Goals View Equipment
Process configuration

Agile, High-Impact Composite Manufacturing for Heavy Commercial Vehicles

Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces.

Equipment and process scope

PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified.

Validation and production planning

Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.

PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.Generated concept illustration for process discussion; not a photograph of the specified machine, a customer facility or a delivered project.

Process configuration

Turnkey Commercial Vehicle LFI Manufacturing Workflow

Configuration sequence from the supplied brief. Material, tool, pressure/temperature basis and complete line balance require verification. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.

01

Automated In-Mold Coating (IMC) Application

Supplied process reference: A dedicated robot sprays a thin barrier coat of water-borne IMC across the heated cast aluminum mold (75°C) to yield Class-A finishes.

TOOL TEMP 70–80°C; IMC FILM THICKNESS 60–80 µM; CONFIRM FOR SELECTED MATERIAL AND TOOLING
02

16 MPa High-Pressure Impingement Proportioning

Supplied process reference: Dual-cylinder metering pumps displace structural polyol and isocyanate at 16.0 MPa under continuous Coriolis mass flow measurement.

WORKING PRESSURE 14.0–16.5 MPA; RATIO TOLERANCE ±0.3%; CONFIRM FOR SELECTED MATERIAL AND TOOLING
03

In-Air Fiber Chopping & Robotic Laydown

Supplied process reference: The robot sweeps the tool; 25 mm glass rovings are chopped at 45 kg/h and wetted in mid-air by polyurethane fans across the open mold.

GLASS LENGTH 12.5–50 MM; GLASS LOADING 20–40 WT%; CONFIRM FOR SELECTED MATERIAL AND TOOLING
Process configuration

Reference Solution Engineering Envelope

Supplied configuration and validation references; material/component results are separate from equipment ratings.

ParameterValue / UnitApplicable Configuration / Conditions
Polyurethane Fluid Discharge Output100 to 500 g/sContinuous variable high-pressure axial piston proportioner; supplied configuration or material target, pending the applicable original records
Continuous Glass Chopper Rate10 to 60 kg/hourHigh-speed electric rotary chopper with tungsten blades; supplied configuration or material target, pending the applicable original records
Chopped Fiber Length Envelope12.5 to 50.0 mmProgrammed rotary knife drum with step adjustments; supplied configuration or material target, pending the applicable original records
Required Mold Clamping Force200 to 400 Tons (Low pressure)Low-cost precision cast aluminum or forged steel tools; supplied configuration or material target, pending the applicable original records
Charpy Notched Impact ResistanceGreater than or equal to 45 kJ/m²ISO 179 testing on 25 mm long-fiber composite core; supplied configuration or material target, pending the applicable original records
Tooling Capital Expense SavingsUp to 60% reduction vs SMCDriven by lower in-mold pressure permitting aluminum tools; supplied configuration or material target, pending the applicable original records
Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.

Core Equipment for This Solution

PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified.

View All Machinery
PRIMARY

Robotic LFI System | Composite Body Panels

Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces.

HF-PU SERIES 1 MODEL

Core Advantages of Haifeng LFI Systems

Configured equipment functions and interfaces for the selected material and tooling.

2x Impact Toughness vs SMC

Supplied configuration function: Entangled 50 mm long glass fibers absorb severe road impacts without brittle cracking. Project-dependent performance requires validation.

60% Tooling Budget Cut

Supplied configuration function: Low cavity pressures (< 3.0 MPa) allow the use of cast aluminum tooling, slashing initial model development costs. Project-dependent performance requires validation.

20% Body Component Lightening

Supplied configuration function: Microcellular structural core lowers panel density, shedding up to 4.3 kg on single truck bumpers. Project-dependent performance requires validation.

Agile Robot-Driven Versatility

Supplied configuration function: 6-axis articulated robots adjust glass lengths and spray densities on the fly matching structural stress zones. Project-dependent performance requires validation.

Related review draft

Related Project Draft

An anonymous project brief from the supplied document. Original attribution, dates, acceptance and outcome records require verification before public use.

Review Project
Concept illustration of Heavy Truck Bumper LFI Molding Project
CHINA / NEW PRODUCTION LINE (0 TO 1)

Heavy Truck Bumper LFI Molding Project in China

Review Project
Planning questions

Frequently Asked Questions

How does LFI eliminate fiber preforming and sheet preparation steps? +
Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces. PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.
Why does LFI require only a 300-ton press for 2.4-meter truck bumpers? +
Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces. PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.
Can this solution produce variable thickness profiles on single parts? +
Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces. PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.
How does in-mold coating (IMC) work with the LFI production cycle? +
Robotic chopped-fiber deposition and PU delivery for configured LFI applications, with separately defined closed-mold RIM interfaces. PU metering, chopper/mixing head, robot and controls; tooling, press, fiber supply and any distinct RIM configuration are separately specified. Open-mold LFI and closed-mold RIM are distinct routes; one configuration does not automatically perform both. PU flow and fiber-chopper capacity constrain achievable fiber content together. The 45% fiber maximum is not assumed at simultaneous maximum PU flow. Impact, mass and tooling savings are part/project comparisons, not general machine guarantees. At the stated minimum PU flow of 100 g/s (360 kg/h) and maximum fiber feed of 60 kg/h, the continuous fiber mass fraction is at most 14.3%; reconcile the stated 15–45% fiber range and instantaneous versus sustained flow basis.

Discuss Your Production Goals

Share your product or drawing, material system, target output, automation needs and factory utilities so the equipment and interfaces can be configured.

Contact us