Studio IDI is a design division of the production company AMA COMPOSITES SRL. In our projects, we rely on the modern technological capabilities of this company and its partners. AMA COMPOSITES SRL is part of the INTERNATIONAL GROUP AMA, created on the basis of AMA spa. AMA spa was founded by Luciano Malavolti in 1967, which continues to be the group’s president today. Today, the AMA group can supply more than 100,000 products in the form of components and equipment for the assembly and maintenance of transport, agricultural and industrial machines. The group includes 11 manufacturing enterprises, 14 distribution branches in major European countries, more than 1000 employees in 20 countries of the world.

AMA COMPOSITES SRL was founded in 2004 in Campogalliano (Modena).

The company sees its mission in supporting the leading role of an international leader in the supply of products, components and equipment for vehicles, industrial and agricultural machines.

In carrying out its activities, AMA COMPOSITES recognizes, accepts and shares a number of moral values that apply both in the internal relations of the company and in external relations with customers and suppliers. AMA COMPOSITES acts as a “full service provider”, covering the entire process of development and delivery of the facility. This takes into account environmental problems and marketing tools, economic and production constraints, aspects of the choice of technologies and materials, solving ergonomic problems and preserving human health.

 

AMA COMPOSITES, AS ALL AMA GROUP COMPANIES, ISO9001 CERTIFIED.

 

The company offers a wide range of high-tech and high-quality manufacturing of plastic products that can satisfy the most diverse needs of international customers.

Thermoforming is one of the oldest and most common methods of processing plastic materials. Vacuum formed products are all around us and play a major part in our daily lives.

The process involves heating a plastic sheet until soft and then draping it over a mould. A vacuum is applied sucking the sheet into the mould. The sheet is then ejected from the mould. In its advanced form, the vacuum forming process utilizes sophisticated pneumatic, hydraulic and heat controls thus enabling higher production speeds and more detailed vacuum formed applications.

Virtually all thermoplastics can be supplied as sheet and vacuum formed. The more commonly used materials: acrylonitrile butadiene styrene (ABS); polyester copolymer (PETG); polystyrene (PS); polycarbonate (PC); polypropylene (PP); polyethylene (sheet and foamed sheet) (PE); polyvinyl chloride (PVC); polymethyl methacrylate (PMMA).

Vacuum forming offers several processing advantages over other forming processes. Low forming pressures are used thus enabling comparatively low cost tooling.

Since the process uses low pressures, the moulds can be made of inexpensive materials and mould fabrication time can be reasonably short. Prototype and low quantity requirements of large parts, as well as medium size runs therefore become economical.

More sophisticated machines and moulds are used for continuous automated production of high volume items like yoghurt pots, disposable cups and sandwich packs.

Unlike other thermoplastic forming processes, where powder or resin are the starting point, vacuum forming uses extruded plastic sheet. AMA COMPOSITES has at its disposal single-station and rotating thermoforming machines with automatic, semi-automatic and computerized control.

The maximum size of the mold holder is 3000 mm x 2000 mm.

With vacuum forming a secondary process may be required to trim the formed sheet to arrive at the finished part. The trimmed waste can then be re-ground and recycled. Other post-forming processes include decoration, printing, strengthening, reinforcing and assembly. A variety of different trimming methods are used to trim the product from the sheet. The type of equipment best suited depends largely on the type of cut, size of the part, draw ratio, thickness of material and the production quantity required. AMA COMPOSITES uses 5-axis milling robots for this.

LWRT technology was born in the late 90s in the automotive sector with the goal of reducing the weight and cost of various automotive components, while maintaining excellent properties in terms of durability, sound insulation, heat transfer, corrosion resistance, as well as high rigidity and impact strength.

These are solid materials combined together to offer the end users the specific properties they require. They are the basis of a compound formed by fiberglass and thermoplastic resin (PP, PC, etc.) with a variable density of 600 g/m² to more than 2000 g/m², which provides maximum flexibility in terms of mechanical strength; subsequently, using low-pressure thermocompression, we can combine the above foundation with various external materials (sandwich), such as PVC, TPO, fabrics with or without PU, non-woven materials, microfiber, etc., providing an aesthetic and high-quality result high level.

Cutting and finishing are carried out using a 5-axis waterjet robot.

This technology represents the best solution for the production of large parts for the automotive sector (door panels, dashboards, the inside of the trunk, aerodynamic bottoms), but can be used with excellent results in sectors such as recreational vehicles, tractors, cars earthmoving, combine harvesting, forklift and special machines.

The RTM-process, “Resin-Transfer-Moulding” is a processing technology to produce fibre reinforced composites (Glass Reinforced Plastic, GRP).

Carbon, glass and aramid fibres are the most well known reinforcing fibres, which are impregnated with a matrix system (Resin-hardener mixture) and processed to produce components.

In the RTM-process the semi-finished fibres are either directly or in the form of a preform placed into a mould comprising a lower and an upper half. After the mould is closed the matrix system is injected into the mould cavity using an injection moulding machine at pressures of up to 35 bar. The hardening starts instantly within the heated mould.

As the component is produced and hardened in a closed mould, the component has smooth surfaces on either sides, consistent wall thickness and fibre volume content in addition to dimensional accuracy. Thus this technology is most suited for production of components that are exposed to heavy structural stresses or need to meet special requirements in terms of dimensional accuracy, stability and reproducibility.

Vacuum Resin Transfer Moulding (VRTM) is the operation of manufacturing composite pieces inside a vacuum that is fixed by two sections mould. The VRTM operation utilizes a semi rigid upper mould that contribute in producing perfect details of the moulded surface and further definition such as encapsulated surface textures. The mould is built with two sections; an internal resin section and an external vacuum section. The lip area between the two sections is emptied to provide the essential fixing force. The vacuum leaks through the sections are reduced significantly due to the safety ability of the sections. Vacuum is applied to the mould bore and the resin is injected under soft pressure into an external feed pipe running on the outer boundary of the basic. This outlying injection method provides the best track to fill the mould, with less reaction pressure against the fixing force.

The option of having a partial automation and full automation makes RTM process a unique production technology suitable for serial production of complex, three-dimensional and continuous fibre-reinforced components.

Structural Reaction Injection Moulding (SRIM) is a process that produces components with high fibre density and is a more durable and cost-effective alternative to traditional GRP moulding.

Typically SRIM parts are used in a wide range of markets:

vehicle (buses, automotive and truck), medical equipment, aerospace. Typical components are dashboards and interior vehicle trim, hoods of tractors, external body parts of technological equipment. With SRIM, Glass Fibre reinforcement material is laid into a mould with a cavity in the shape of the product. The mould is closed and polyurethane (PU) is injected into the cavity by pressure. This process produces components with high fibre density and is a more durable and cost-effective alternative to traditional GRP moulding. Long fiber injection molding (LFI) technology is in many ways an improved, upgraded version of SRIM, as it provides similarly strong and stiff parts via a quicker and more efficient process.

The process has an extremely short cycle time, with a finished part usually created every 3-5 minutes. It is also labor-efficient due to the high mechanization of each step of the process.

The SRIM process often uses a UEV (Vinyl Skin) or a thin gauge vacuum forming (АBS+PММА) laid into the mould initially. The glass fibre and PU then becomes a reinforcement media on the reverse of the UEV or forming, and with the close mould process produces a rigid component that can be designed with additional stiffening ribs and a variety of inserts for component fixing.

Since such a low-viscous material exerts very little stress on the tool, SRIM tooling can make large and complex, 3-dimensional parts at a fraction of the tooling investment of a comparable injection molding tool. SRIM is not necessary all the time, but it is an important tool to have available so that we can completely meet your project goals.

Thermoplastic molding is a reversible molding process by which pellets of plastic are melted, forced into a mold to assume their final shape and then quickly cooled to harden.

Thermoplastic injection molding can be used to produce anything from car door panels to cell phone cases with a high degree of accuracy and surface finish. Thermoplastic molding has a very high production output rate, making it quicker than other methods of plastic manufacturing. This means thermoplastic molding is a very cost-effective and efficient form of plastic manufacturing. For these reasons, it has become the industry standard for producing plastic parts.

Thermoplastic injection molding can be accomplished with just about any engineering-grade plastic resin. But that's not even including more general resins. Engineering grade resins are typically utilized to create final prototypes before manufacturing, while general resins are used to craft early prototypes or parts of a product that are of lesser importance. When we talk about general resins, we're referring to the likes of ABS, nylon, PET, polypropylene, polyethylene, and TPE. Engineering-grade resins consist of Lexan, Noryl, Valox, and Ultem. As we previously mentioned, the plethora of plastic resins that can be processed via thermoplastic injection molding allows product developers to experiment with different materials and surface finishes for their products.

Thermoplastic molded products tend to contain greater strength than plastic machined parts. This is due to the ability to add fillers to the base material, adding strength to the finished product.

There are many fillers and additives commonly used in plastics. To increase rigidity: glass fibers, carbon fibers, talc. To reduce rigidity: plasticizers. To reduce cost: calcium carbonate. To improve processing: mold release, lubricants. For special applications: flame retardants, UV stabilizers.

Also, thermoplastic injection molding gives manufacturers the ability to use multiple types of plastic at once, through the use of co-injection molding. AMA COMPOSITES has several molding machines with manual, semi-automatic and computerized controls, up to a maximum of 1500 tons.

 

First developed in the late 1930s, polyurethanes are some of the most versatile polymers. They are used in building insulation, surface coatings, adhesives, solid plastics, and athletic apparel.

Polyurethanes can be produced in four different forms including elastomers, coatings, flexible foams, and cross-linked foams. Elastomers are materials that can be stretched but will eventually return to their original shape. They are useful in applications that require strength, flexibility, abrasion resistance, and shock-absorbing qualities. Thermoplastic polyurethane elastomers can be molded and shaped into different parts. The quality of polyurethanes has steadily improved since they were first developed. Research in a variety of areas should continue to help make superior materials.

AMA COMPOSITES produces polyurethane mats (with or without additional additives and foams) for interior cabins, both in agriculture and in construction, where noise and vibration reduction combined with high-quality appearance play a key role in the development of the project.

Properties and characteristics: comfort and softness, support and resistance, hygiene, high flexibility, noise, and vibration absorption. The structure of the mat can be reinforced with inserts and additives to achieve the desired rigidity and hardness. We can also combine our AMATHERM radiant technology to make the carpet a real heating element. Ideal for electric vehicles.

Aerogel are substances we encounter in our everyday lives!

Take for instance the meringues which pastry cooks have been preparing since time immemorial: meringue consists of whipped egg white and sugar and when baked, a feeling of heat is immediately noticed.

This phenomenon is due to the fact that the air contained in the meringue is trapped in millions of microscopic bubbles. As in the case of the amorphous silica Aerogels, the air contained in the meringues cannot therefore circulate and exchange heat and this way it becomes an excellent heat insulator. The first Aerogel molecules date back to 1931, the year Steven Kistler of the College of the Pacific at Stockton in California discovered the way to dry the gel without it collapsing.

By bringing the liquid to the super-critical state, and therefore bringing both temperature and pressure to super-critical state, the pressure is gradually reduced: the super-critical fluid is then expelled by the gel without the destructive effects caused by surface tension. What remains is an Aerogel, still the lightest solid substance existing in the world, along with graphene, consisting of 98% air and 2% amorphous silica, the main component of glass. Besides being extra-light, Aerogel is an excellent heat insulator and withstands very high temperatures. Aerogel is a type of synthetically amorphous silica which differs from crystalline silica. Synthetically amorphous silica has no effects on health – as declared by the OECD (United Nation’s Organization for Economic Cooperation and Development) – unlike crystalline silica, which can cause respiratory diseases such as silicosis.To best use the extraordinary heat characteristics of the product, a system has been patented to be able to trap the Aerogel inside a fibrous structure, ensuring the same levels of insulation, without having to do without the easy movement and transformation of the product.

Aerogel-based products have shown themselves to maintain the same heat insulation performance even under considerable mechanical stress. This also makes it possible to use the material in permanent and/or dynamic load conditions in total safety.

Aerogips® is a panel designed for the interior heat insulation of building structures which require maximum level of insulation in the least possible space. Aerogips® is a high-performance insulating panel made up of a nano-technological insulating substance containing Aerogel coupled with a sheet of plaster with high-density coating for excellent heat-acoustic comfort.

Aeropan® Basic is a panel made using an Aerogel-based blanket. Its flexibility characteristics and the particular two-sided finish, made up of a fiberglass mesh, make it particularly suitable for correcting thermal bridges, the heat insulation of spaces between walls (including in dry structures), or for flat application on roofs and terraces.

AMA AEROGEL® represents an important new step in the development of nanotechnological insulation products based on silica airgel.

It consists of a flexible insulating matrix based on glass fibers and a high concentration of nanoporous airgel that can guarantee the best thermal performance in any application.

In search of maximum thermal protection, AMA AEROGEL ® is an important insulator due to its unique properties: extremely low thermal conductivity - 0.016 W / (m * K) -, excellent flexibility, resistance to compression, hydrophobicity and ease of use. AMA AEROGEL® can be used in the temperature range from -200° C to + 450° C. AMA AEROGEL®, available in 3, 6 or 10 mm thicknesses, optimizes the interior spaces in commercial and residential buildings, guaranteeing the highest thermal resistance values for the same thickness with conventional insulation materials.

Aeroproof is a panel designed for heat insulation and the preparation of the substrate for the subsequent waterproofing of all types of flat and pitched roofs, for civil and industrial buildings. Aeroproof is a high-performance insulating panel made of a nano-technological insulating product containing Aerogel coupled with a bituminous membrane able to ensure excellent heat insulation, compression resistance, dimensional stability and a first waterproof layer.

MORE INFORMATION:

 

www.ama.it       www.amacomposites.it    www.aeropan.it

 

VACUUM FORMING

LWRT

(Lightweight Reinforced Thermoplastics)

RTM

(Resin-Transfer-Moulding)

SRIM

(Structural Reaction Injection Molding)

THERMOPLASTIC INJECTION MOLDING (TIM).

HD-PUR

AEROGEL – SUPER INSULATION MATERIALS.

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