Lightweight design made efficient - FFT Produktionssysteme sets standards in industrial lightweight construction
Lightweight construction is a key technology in many areas of industry, not only to achieve the goals of climate protection and sustainability, but also to increase production output. The term lightweight construction covers all approaches and technologies that contribute to reducing the weight of parts and components, thereby increasing resource efficiency. This can be achieved through the use of lightweight materials, the optimised use of existing materials or the use of innovative manufacturing processes.
FFTlightweight - Innovative lightweight solutions for the production of tomorrow
FFT supports its customers in optimising their production processes to achieve lean production. From the initial idea to commissioning and after sales, FFTlightweight offers customised solutions and standardised FibreTEC profiles. A technology that combines high strength and low weight. FFTlightweightcomprises all lightweight solutions from FFT, which are offered as a standardised product or as an individual development.
A central element is the FibreTEC process, which is based on the winding technology of carbon fibre-reinforced structures. This technology makes it possible to produce high-strength, lightweight and customised components.
FFTlightweight FibreTEC profiles - Standardised lightweight profiles with a modular system
FFTlightweight FibreTEC is a robot-guided technology process in which carbon fibre impregnated with resin is 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.
Modulated 3D carbon fibre geometries: A new approach to lightweight construction
FFTlightweight FibreTEC 3D are highly dynamic, resilient structural components that can be customised and contribute to weight reduction. The technology is based on the use of carbon fibre composites (CFRP) in complex, freely designable geometries. With FibreTEC 3D, three-dimensional carbon fibre structures can be created using winding or fibre deposition processes to produce geometrically sophisticated components with high strength and low weight.
The advantages at a glance
The carbon fibre geometries from FFT impress with a perfect combination of lightness, precision and modular adaptability - ideal for use in demanding lightweight construction and automation environments.
Weight saving:
Compared to aluminium or steel frames, weight reductions of up to 40 % can be achieved. The lower dead weight not only improves energy efficiency, but also reduces the load on robots, handling systems and structures.
Geometric freedom:
The freely configurable components enable optimum accessibility and ensure shorter swing-out and reaction times in dynamic applications such as robotics. This allows motion sequences to be realised faster, more precisely and more efficiently.
High rigidity with low weight:
Thanks to the carbon fibre shell, loads are transferred optimally, reducing bending and vibrations to a minimum. The result: exceptional stability combined with significantly reduced weight - a real advantage for highly dynamic processes.
Modular integration:
Whether as a tool frame for grippers or as a structural element in series applications, FFT's modular solutions are scalable, customisable and can be seamlessly integrated into existing systems. The result is a lightweight construction concept that combines efficiency and flexibility.
Innovative lightweight profiles for light and stable production.
With the FFTlightweight FibreTEC Profile, FFT offers a modular CFRP system with aluminium deflection points. The aim of this product range is to make the advantages of carbon fibre technology available for industrial use in the form of modular components. The profiles are characterised by a particularly lightweight yet highly stable design. The modular system also has integrated threads and pins for secure fastening, which significantly reduces assembly time. FFT offers a wide range of profiles in different sizes, each with specific properties that can be perfectly customised to individual requirements. The advantages speak for themselves:
- Already integrated threads
- Up to 40% weight advantage compared to aluminium profiles
- Better strength and stability compared to aluminium profiles
- Better tolerance compared to aluminium profiles
- Reduced inertia on the robot arm compared to aluminium profiles
- Use of smaller robots possible compared to aluminium profiles
Efficient modular system thanks to profile connections
The FFTlightweight FibreTEC Connectors complete the innovative CFRP profiles from FFT to form a unique modular system that offers all the connection options that the heavy aluminium profiles also have. The modular system combines ultra-light CFRP profiles with precision-manufactured aluminium connecting elements. These planar connector plates enable stable connections of CFRP profiles in one plane and simultaneously save weight as well as transport, production and storage costs.
The result is a modular and economical solution for constructions in lightweight construction, mechanical and plant engineering or automation technology.
Connection options
Various connection types can be realised with flat connecting elements in 5 mm and 10 mm profile thickness:
- T-Connector: Connection of two or three profiles in a T-shape - ideal for frame constructions.
- L-Connector: Corner connection for 90° constructions, e.g. for frames and enclosures.
- H-Connector: Parallel connection of two profiles for robust cross bracing.
- X-Connector: Cross-shaped connection of four profiles - the central node in lightweight construction.
Variants at a glance
The connectors are available in several sizes to combine different profile types:
- C80 - for SW80 profiles
- C100 - for SW100 profiles
- C80/100 - to connect SW80 with SW100 profiles
The FibreTEC system thus offers maximum flexibility, simple assembly and reliable stability for modular lightweight constructions that can easily replace conventional aluminium frames.
Research and development: lightweight construction and the future
As part of the research projects funded by the Federal Ministry for Economic Affairs and Energy (BMWK), FFT is continuously developing new technologies in the field of lightweight construction and automation. This results in practical solutions for demanding applications - particularly in the aviation industry:
■ UniFix: mobile, modular clamping field for handling aircraft structures. The automated mounting of up to ten different flap and fin shell elements with lengths of up to eight metres enables maximum flexibility in assembly.
■ SeMoSys: Automated section assembly with subsystem installation for innovative aircraft architectures. The presentation frame made of FibreTEC profiles, laser-tracked contour blocks and a load-optimised steel frame ensure maximum positioning accuracy.
■ DHiiP: CFRP gripper for the precise handling of flexible preforms and mould cores in the RTM process. The particular challenge here lies in the high placement accuracy and fully automated process control.
■ kaMeL: Automated assembly platform for joining aircraft sections along the longitudinal seam. The use of CFRP integral grippers with a length of up to six metres meets the highest requirements in terms of rigidity, stability and positioning accuracy.
These research projects emphasise FFT's commitment to the consistent further development of lightweight construction, automation and precision - with a clear focus on industrial series applications and sustainable production processes.
