Technologies

HIGH STANDARD FOR HIGH-QUALITY PRODUCTS

As well as processing simple, non-reinforced materials, polymers with special characteristics like thermal conductivity or electrical conductivity are also used. As a member of the MÜLLER TECHNOLOGIE GROUP, Sky-Engineering has at its disposal a profound know-how of the development, design and application of state-of-the-art production technologies in plastic injection moulding.

• MODERN FLEET OF MACHINES WITH CLOSING FORCE RANGE OF BETWEEN 25-400 TONNES
• MULTI-COMPONENT TECHNOLOGY
• PROCESS VARIANTS OF INNER GAS PRESSURE
• INJECTION MOULDING AROUND METALLIC AND TEXTILE INSERTS
• TOOL CONSTRUCTION (VOLUME PRODUCTION AND PRE-PRODUCTION)

FORM AND FUNCTION PUT TO THE TEST

We realise product ideas from 3D data records and models to fully functioning samples – in pre-production and small production runs too. The completeness and continuity of what we can offer in prototyping shortens your development times and optimises your result, ensuring optimum know-how.

• FOAM MODELS
• SINTER PARTSILE
• CASTS
• INJECTION MOULDED PARTS FROM PRE-PRODUCTION TOOLS
• ELECTRONIC COMPONENTS
• MECHANICALLY PROCESSED PARTS
• DESIGN MODELS
• RAPID PROTOTYPING (STEREO LITHOGRAPHY, LASER SINTERS, SILICONE SHAPES AND PRE-PRODUCTION TOOLS)
• FUNCTION PROTOTYPES

COMPONENTS THAT STAND UP TO HIGH LOADS

Until now carbon fibre-reinforced thermosets have been produced in a manual lamination process. Long delivery times and erratic quality levels made it difficult to use the market potential of this innovative material for mass production. Thermofusion has now developed production technologies and processes which allow for the mechanical and fully automatic production of carbon components for the first time ever.

Carbon fibre- or fibre glass-reinforced materials are used for plastic components which are subject to high mechanical loads. These can be cost-effectively processed in the injection moulding process

• THERMOFUSION PROCESS (FULLY AUTOMATED PRODUCTION OF CARBON FIBRE-REINFORCED COMPONENTS WITH VISIBLE FABRIC MATRIX)
• PROCESSING HIGH-STRENGTH LONG FIBRE MATERIALS IN THE INJECTION MOULDING PROCESS

SURFACE FINISH FOR HIGH-QUALITY PRODUCTS

The processed materials used in the first class seating area must satisfy very stringent aesthetic and durability requirements. The high-quality surfaces have to withstand the loads and influences of flying for many years and must not lose any of their high-quality appearance during this time.

Highly trained staff, state-of-the-art technologies and effective methods of quality assurance make possible the production of series products with surfaces displaying a constantly high quality

• USING THE GRAIN TO GIVE TEXTURE TO PLASTIC PARTS
• SOFT TOUCH AND SPECIAL EFFECT PAINTWORK, DAY-AND-NIGHT DESIGN
• DECORATIVE COATING (ROOT WOOD, CARBON AND METALLIC SURFACES)
• LEATHER AND MATERIAL LAMINATION
• CHROMATING, ANODISING, ZINC PLATING, VIBRATORY GRINDING, SAND BLASTING, GOLD COATING, SPRAY PAINT WORKSHOP, LASING
• PRINTING AND LABELLING

THE HIGHEST PRECISION

The functionality of components and assemblies is monitored throughout the entire production phase on the basis of test instructions. Parts lists and operating instructions ensure that the design corresponds to the drawing. Batch purity is guaranteed through the issuing and documentation of serial numbers.

• ULTRASONIC WELDING OF PLASTIC PARTS
• RESISTANCE WELDING OF METAL COMPONENTS
• BONDED JOINTS FOR A WIDE RANGE OF MATERIAL COMBINATIONS
• CABLE ASSEMBLY
• SOLDERING ACCORDING TO IPC 610 (AS SUITABLE FOR AVIATION)

THE HIGHEST-QUALITY MEASURING TECHNOLOGY

At all phases of product realisation, both the components and assemblies produced in-house and the components bought in from outside are subject to a complete quality assurance process using state-of-the-art measuring technology procedures.

• 3D coordinate measuring technology
• Comparison of measurement and planning data
• Calibration of measuring gauges
• Production of automated measurement programs (incoming goods / outgoing goods)