We think light, innovative and efficient!
We support our customers in optimising their production processes to achieve lean production. From the initial idea to commissioning and after sales, FFT offers lightweight construction solutions and standardised FibreTEC profiles. A technology that combines high strength and low weight - that's what drives us. That's what sets us apart. This is FFTlightweight
Our services in lightweight construction
FFT not only realises turnkey production systems for customers worldwide, but has also been offering a broad product portfolio for several years. The quality of the components and safety for use in automated environments are particularly important to FFT. FFTlightweight comprises all lightweight solutions from FFT, which are offered as standardised products or as individual developments.
Production Concepts
Our lightweight production concepts are customised for your application in terms of construction, design and function. As with turnkey production systems in plant engineering, we utilise our project strength to implement your requirements.
FibreTEC
FibreTEC is the latest innovation in the world of lightweight construction at FFT. In addition to standardised profile strands in various dimensions, we can also use this technology to wind 3D geometry elements, thus enabling a mass reduction of almost 50% compared to aluminium components.
Integral
The hybrid design consisting of a steel body (for the geometric functions and dimensional accuracy) and a carbon fibre coating (for the required rigidity) guarantees extremely high bending stiffness with simultaneous vibration damping. We often use these grippers for high-precision tasks such as framing in automotive production.
Why lightweight construction?
Handling tasks in production often fail due to the weight of the product and tool to be transported. The so-called payload problem quickly arises, in which the total mass of the gripper and component exceeds the maximum payload of the robot. The rule of thumb is: the lighter the tool, the heavier and larger the component to be transported can be.
A promising solution to this problem is the use of fibre composites. FFT has therefore developed its own composite tools that can significantly reduce the weight.
Lightweight construction - reference from practice
The innovative combination of a scissor lift system made of FFTlightweight FibreTEC profiles with an FFTlightweight Integral frame saved 1.7 tonnes of weight compared to the previous solution using a steel structure! The use of carbon moulds therefore not only helps to reduce energy costs, but also cuts CO2 emissions. In addition, the shorter cycle time and efficient use of space significantly optimise the movement sequences. Overall, these improvements lead to a noticeable increase in performance, which significantly increases both the efficiency and sustainability of the system.
Production Concepts
FFT has been active in plant engineering since 1974 and therefore has over 50 years of experience in the automation of the production of various end products. We bring our expertise to the production sites of major OEMs and well-known manufacturers, not only in body-in-white construction in the automotive industry, but also for white goods, rail vehicles and aviation. Lightweight construction solutions or projects in which the product itself is made of lightweight materials are becoming increasingly important. In the automotive industry, there is a growing focus on reducing energy and resource consumption, as well as on optimizing technical performance characteristics. Lightweight design concepts are viewed as a potential approach to weight reduction and performance optimization.
Standardised lightweight profiles with modular system FFTlightweight FibreTEC
FFTlightweight FibreTEC is a robot-guided technology process in which carbon fibres impregnated with resin are wrapped around structural components to form a high-strength structure after curing. FibreTEC itself is therefore a process similar to 3D printing. FFT has developed a standardised lightweight profile from this technology and also offers the production of customer-specific 3D components using this technology.
3D
By FFTlightweight FibreTEC 3D , we mean highly dynamic, resilient structural components that can be customised and contribute to weight reduction. The components are wound using FibreTEC technology.
We look at your product or your application together to consider how we can reproduce your component using wound carbon fibres. It doesn't matter whether it's a tool, such as an ultra-light handling gripper for cobots, or a component for the end product that needs to be made lighter.
- Up to 63% weight reduction
Profiles
The FFTlightweight FibreTEC profile is our answer to standard aluminium profiles that are too heavy. The modular system already has integrated threads and pins for secure fixing, which significantly reduces installation time. We offer you a wide range of profiles in different sizes, each with specific properties that are perfectly tailored to your needs. The advantages of the system speak for themselves:
- Pre-integrated threads
- Up to 40% weight advantage*
- Better strength and stability*
- Better tolerances*
- Reduced inertia on the robot arm
- Use of smaller robots possible*
*Compared to aluminium profiles
Connectors
Our FFTlightweight FibreTEC Connectors complete the profiles to form a unique modular system that offers all the connection options that the heavy aluminium profiles also have. The great advantage of the square basic profile is the planar connecting elements, which not only save weight, but also transport, production and storage costs.
The connectors are available in the following versions:
- C80 - for SW80 profiles
- C100 - for SW100 profiles
- C80/100 - to connect SW80 with SW100 profiles.
Integral
FFTlightweight INTEGRAL are our patented lightweight construction systems for various tasks. These integral solutions follow a hybrid design consisting of a lightweight sheet steel body wrapped in a carbon fibre shell. The spatial geometry structure is arbitrary and is developed according to your specifications and requirements. Compared to certain aluminum structures, the system's weight can be reduced by up to 40%. Depending on the application, the lower moving mass may allow for the use of smaller robotic systems and can affect the dynamic and energy consumption parameters of the overall system.
Lightweight construction references
FIBRETEC
GREATER
General system and process designs for a lightweight robotic handling application for handling large metal structures.
ANNIVERSARY CONGRESS
Exhibition of our FibreTec technology process as well as integrated in our exhibition walls, bar tables or seating.
INTEGRAL
DHIIP
Development of a digital product hierarchy for data acquisition in the production of CFC components. Technological design for the handling and integration of flexible preforms in a heated RTM mould.
GREIFER
These grippers can reduce weight by up to 40% compared to comparable steel structures. Depending on the application, the lower moving mass may allow for the use of smaller robotic systems and can affect the design and dynamics of the handling system.
UNIFIX
Development of a mobile, modular and multifunctional clamping field for handling aircraft structures.
MULTIFAL
The project includes the welding of two-part fuselages and the automated welding of longitudinal seams of up to 8 metres in length for next-generation thermoplastic aircraft fuselages.
PRODUCTION CONCEPT
BRAIDING MACHINE
Highly flexible turnkey system with 2 automatically changing braiding wheels, 4 cooperating robots and automatic fibre angle control for different products.
H2 STRUCTURE TANK
Development of a new manufacturing system for the production of structure-supporting, fibre-reinforced plastic hydrogen tanks made of thermoplastic FRP in wing segments.
CAMEL
Development of an automated assembly platform for joining aircraft sections along the longitudinal seam and for the automated application of sealing compound at specific joining points.
SEMOSYS
Development of an automated section assembly with subsystem installation for innovative aircraft architectures and construction methods.
AUTOMATION FOR ULTRASONIC WELDING
Assembly and milling of various wing shell elements.
UNIFIX
Development of a mobile, modular and multifunctional clamping field for handling aircraft structures.
RESEARCH
DHIIP
Development of a digital product hierarchy for data acquisition in the production of CFC components. Technological design for the handling and integration of flexible preforms in a heated RTM mould.
CAMEL
Development of an automated assembly platform for joining aircraft sections along the longitudinal seam and for the automated application of sealing compound at specific joining points.
H2 STRUCTURE TANK
Development of a new manufacturing system for the production of structure-supporting, fibre-reinforced plastic hydrogen tanks made of thermoplastic FRP in wing segments.
AUTOMATION FOR ULTRASONIC WELDING
Assembly and milling of various wing shell elements.
UNIFIX
Development of a mobile, modular and multifunctional clamping field for handling aircraft structures.
SEMOSYS
Development of an automated section assembly with subsystem installation for innovative aircraft architectures and construction methods.
Our customers and partners in lightweight construction
Many large OEMs from the automotive and aerospace industries already rely on our expertise. Together with renowned research partners, we are developing new concepts and smaller companies are already convinced by our performance.
CHALLENGE US! We look forward to getting in touch with you:
Send us your concept idea, your automation requirements or a description of your geometric component that you want to reduce in weight. We look forward to presenting our standardised portfolio to you, but also to developing new solutions together with you.
Your FFTlightweight contact:
