CNC-Cut Foam Core Kits Reduce Resin Use, Improve Mold Fit

Advanced Kits. Source | Diab

Diab (Laholm, Sweden) has introduced Advanced Kits, a foam core kitting solution developed to help composites manufacturers reduce part weight, cut resin consumption, and improve mold fit and surface finish. The kits combine Diab’s kitting and composites manufacturing expertise with custom software developed specifically for advanced core shaping, allowing each kit to be optimized to the local curvature of a customer’s mold.

Each kit detail is machined using a proprietary CNC-cut profile that cuts the core partway through its thickness, eliminating the need for a scrim backing and leaving a smooth surface and curvature on the mold side. Perforations and grooves can also be added to the core surface to distribute resin without a separate flow mesh, which the company says results in improved formability, reduced resin consumption and better surface finish.

Diab reports that Advanced Kits reduce resin consumption by up to 60% compared with a traditional GS kit. The company also cites reduced structural weight, and improved surface quality from an intact foam layer without GS scrim closest to the mold-side fiber reinforcement.

Each core detail is CNC machined for accuracy and repeatability and can be designed with zero springback, improving fit in the mold; varying bevels can also be incorporated. Diab says the process improves quality and consistency of infusion, including a reduced risk of race-tracking, and that allowing larger foam details can speed up the layup procedure while maintaining repeatability between kits. Add-ons such as laser tracking lines or Kit-Locks can also be incorporated into the foam kit to aid positioning.