Addressing Common Questions about Pultruded Products

Jun. 17, 2024

Addressing Common Questions about Pultruded Products

Contact us to discuss your requirements of FRP Special-Shaped Equipment. Our experienced sales team can help you identify the options that best suit your needs.

Pultruded fiberglass has earned its place as one of the most versatile construction materials in the world. Its sustainability and unique properties allow it to successfully replace traditional materials like wood, aluminum, and steel.

This post provides many of the frequently asked questions about pultruded products.

What Is Pultruded Fiberglass?

Pultrusion refers to the process by which fiberglass is made. This process involves either drawing the fibers through a special resin bath or injecting the fibers with resin.

Once the fiber has been wetted, machines shape it to the specified dimensions and then pull it into a preheated steel die.

The heat causes the resin to cure as it is pulled through the die. In this manner, fiberglass can be pultruded according to virtually any specification or shape, including sheets, rods, poles, angles, bars, tubes, and channels.

Pultruded fiberglass &#; known as fiberglass &#; is a unique structural material combining fiber reinforcements and thermosetting resins.

Pultruded fiberglass must have a constant cross-section.

Is Pultruded Fiberglass the same as Fiberglass Composite?

Very often, there is confusion about fiberglass and the various naming conventions used.

Aside from "fiberglass" and "pultruded fiberglass," manufacturers may also use any of the following terms:

Fiberglass Composite
Glass-Reinforced Plastic (GRP)
Fiber-Reinforced Plastic (FRP)

All of these names refer to virtually the same thing: a composite constructed using two materials: fiber and resin.

The fiber provides reinforcement, while the resin provides the body &#; technically speaking, the matrix &#; necessary to give the product shape.

The main distinction to be aware of when it comes to fiberglass is the production method.

While most fiberglass structural components are manufactured by means of the pultrusion process discussed above, fiberglass may also be manufactured by means of compression molding, resin transfer molding, open-mold spray-up, and casting.

For this reason, pultrusion-based manufacturers often make a point of referring to their product specifically as pultruded fiberglass, in order to avoid confusion with fiberglass produced by other methods.

What Is Resin Made Of?

Resin is the ingredient most likely to vary from one type of fiberglass to another. The main types of resin that have been used in fiberglass pultrusion include:

Polyester
Vinyl Ester
Epoxy
Polyurethane

Polyester remains the most widely utilized resin. While it does not excel in any one category, it offers a great overall blend of properties, being relatively low cost, easy to process, quick to cure, and relatively strong.

Vinyl ester is somewhat more costly than polyester but results in more durable fiberglass.

For the most part, vinyl ester has a molecular structure much like that of polyester. The difference is that vinyl esters contain fewer ester groups.

This gives the fiberglass a significantly greater degree of resistance to water and chemical corrosion.

Epoxy-based fiberglass demonstrates even greater durability, strength, and chemical resistance. In addition, epoxy increases the fiberglass' resistance to high temperatures.

That said, epoxy has more complex processing needs, and also tends to carry a higher material cost.

Finally, many pultruded fiberglass manufacturers have begun using polyurethane resin in recent years.

While polyurethane does present certain challenges from an equipment standpoint, its performance characteristics are second to none.

Polyurethane has been shown to outperform other resin types in terms of strength, toughness, and resistance to heat, ultraviolet light, and environmental factors.

Is Fiberglass Conductive?

Conductivity may refer to two different things: thermal conductivity and electrical conductivity.

Virtually all materials display some degree of thermal conductivity &#; in other words, allowing heat to move through them. That said, fiberglass tends to have a relatively low thermal conductivity, especially compared to metal.

Electrical conductivity is defined as the ability of a material to transmit electrical charge. Metals such as steel, copper, and aluminum all exhibit different degrees of electrical conductivity.

Fiberglass, by contrast, is generally categorized as being a non-conductive material, one that can even be successfully used as an electrical insulator.

Fiberglass thus holds a distinct advantage over metals in cases where conductivity must be strictly prohibited.

However, in certain situations conductivity may be a desirable trait. In those cases, manufacturers can often integrate additional composite materials to give the fiberglass a degree of conductivity.

For instance, aluminum or carbon fibers can be introduced along with the glass fibers when pultruding the fiberglass.

What is the Impact of Electromagnetic Waves on Fiberglass?

As the modern world comes increasingly to rely on wireless communications technology, traditional building materials must be re-evaluated in terms of their effect on electromagnetic signals.

Common materials such as concrete, steel, and aluminum all exhibit significant inhibiting effects when it comes to electromagnetic waves.

Basically, any material that is either magnetic or electrically conductive will block or distort a significant amount of the wireless signals it encounters. Fortunately, fiberglass is neither magnetic nor electrically conductive.

As a result, fiberglass is, for the most part, transparent to radio waves, cellular frequencies, and other forms of electromagnetic signals.

For this reason, fiberglass has gained a significant amount of traction within the telecommunications industry.

In particular, fiberglass has become a material of choice when it comes to erecting cell tower screens. Likewise, fiberglass makes a great choice as a protective covering for antennas and other telecommunications equipment.

Pultruded fiberglass offers a wealth of benefits that make it one of the strongest, most durable, and most cost-effective building materials currently available.

If the idea of structural fiberglass is still new to you, don't worry. Reputable manufacturers know just how to design custom fiberglass to meet virtually any need.

To learn more about the different types of fiberglass products they can manufacture for you, please do not hesitate to reach out to the industry leaders at Tencom Ltd.

What is the lead-time for production tooling?

Tencom can typically manufacture a production tool in 6 to 8 weeks. This may vary depending on the workload at the time the order is placed.

Which resins are most often used in pultrusion's?

Tencom uses include epoxy, high-temperature vinyl ester, fire retardant polyester, fire-retardant vinyl ester, polyurethanes, and bonding resins. The materials are then pultruded using our exclusive process and equipment.

Can fiberglass products be produced in different colors?

Yes. For branding and identification purposes, Tencom can produce pultrusions in different colors.

Are there specialty resins that make pultruded products fire retardant?

For more used fiberglass water tanks for saleinformation, please contact us. We will provide professional answers.

Additional reading:
Hay Baling Wire vs. Twine: Which Is More Effective?
10 Questions You Should Know about Choosing Artificial Stone vs. Translucent Stone
Will Galvanized Steel Rust in Concrete?
Things To Consider When Choosing an LED Sign
Cable Bolt
Key Questions to Consider When Selecting Custom Software Development Services
How to Choose Custom Metal Fabrication Parts?

FRPs are manufactured by using glass strand mats combined with resins. Unlike materials like wood and fabric that require additives to be sprayed on after manufacture, FRPs can have fire-resistant and flame retardant properties infused directly in production.

The resins used to bathe the glass fiber mats can feature a wide variety of additives to enhance their durability and offer additional benefits, such as fire-resistant and flame retardant properties.

Flame retardants in FRPs work by releasing chemicals when they are exposed to fire.

These chemicals create either a char layer that smothers the flame and protects the internal composite from further damage, or releasing gaseous chemicals that deprive the flames of oxygen to smother them.

We can also design systems to meet customer&#;s individual specifications.

Is fiberglass affected by temperature extremes?

Fiberglass is relatively unaffected by normal temperature fluctuations. Strengths and flexibility remain consistent between -40 and 250F°. If the application requires an operating temperature outside of this range, special considerations should be taken while designing the product.

How can I get a quote for a custom product?

To get a quote, call 419-865- or . Our engineers will work with you on a design that will meet your individual specifications and provide a quotation. Please have a part/profile drawing available, as well as estimated annual footages and any special tolerances or specifications.

Top 10 Considerations When Buying a CNC Machine for ...

The unique structural characteristics of composite materials and cost-to-weight ratio make it a valuable commodity across a wide range of industries. Having the most versatile CNC machine may be the best investment.

A considerable amount of time and investment goes into finding the right CNC solution to efficiently and effectively machine composites. The last thing manufacturers want is to invest in the wrong machine and be paying for that mistake for years to come. With little room for error, it is important to understand how different materials, machinery characteristics, and machinery options affect machining speed, precision, service, and overall production.

1. Spindle HP & RPM - Consider high RPM, low torque

High-speed Honeycomb Core Machining. Watch a demo of the C.R. Onsrud E-Series.

Material density plays a key role in determining the best spindle RPM, HP, and torque for an application. To aggressively machine hard materials, such as steel and Inconel® , some traditional machining centers typically are equipped with high torque, low RPM spindles that operate at a maximum of 12,000 RPM. When it comes to composites (such as foam, tooling board, or carbon fiber), a high torque, low RPM spindle is too slow to reach optimal chip load and thus results in inefficient (slower) composite machining. Instead, high RPM (18,000 - 24,000), low torque spindles are more efficient in reducing cycle time, lengthening tool life, and improving overall spindle reliability. For the best of both worlds (composite and nonferrous metal machining), consider a spindle capable of running at 20,000 - 24,000 RPM and higher feed rates for lighter-duty materials but also can operate in the 10,000 - 12,000 range for harder materials that need more torque.

2. Dust Containment / Collection - Improve employee safety and machine longevity

Dust Collection Tray, Optional Vacuum Ports. Remove harmful dust and debris from fully enclosed CNC Machines. Watch the machine walk-thru.

Machining composites often creates a large amount of dust and debris that can cause health problems to workers and damage to the machine. Some composite dusts can lead to lung damage if inhaled and some are electrically conductive, so they can damage machine circuits and cause spindle or machine wear at an increased rate. Thus, choosing a CNC solution with sufficient dust collection and properly sealed and covered components is imperative when working with composites. Some additional considerations for handling abrasive material machining include air knife systems, downdraft tables, and/or full enclosures.

5-Axis Programmable Dust Hood. Watch a demo.

Fully Enclosed CNC Router. Reduce harmful debris and airborne particles. Watch a demo.

Air Knife. Remove Dust & Debris with CNC-Controlled Airblasts. Watch up close.

3. 3-Axis vs. 5-Axis - Depends on the part&#;s geometry

When machining complex 3D composite components, a 5-axis machine is more efficient than a 3-axis machine and provides a greater return on investment over time. With a 5-axis machine, multiple sides of a part can be machined without having to manually reposition material or swap out tooling for angled heads. A 3-axis machine can perform multi-face machining as well but at a much slower rate as it requires an operator to stop the machine and reposition the part after each operation. To achieve 5-sided milling, drilling, tapping, and/or sawing operations without a 5-axis machine or without having to manipulate parts, consider adding a 4th axis and utilize angled heads, known as aggregates.

4. Rigidity - For speed, tool life, and machine longevity

Troutman NC, C.R. Onsrud CNC Manufacturing Plant. Take a tour.

Due to the abrasive and unique structure of composites, it is worth investing in a CNC machine with fully reinforced structural integrity and rigidity. A sturdy design reduces vibrations and tool deflection to provide top acceleration/deceleration speeds, long tool life, and low maintenance and repair costs over the lifetime of the machine compared to less rigid, light-duty machinery. From an upfront cost perspective, a machine can be made cheaper by reducing the structure and quality of its components; however, it will fail to have the longevity of a better built machine and ultimately will result in a higher total cost of ownership.

5. Work Envelope - Make sure it fits, and consider the benefits of larger tables

Large-format Tooling Board Demo. 917 Porsche. Watch now.

In addition to the type of composite material being machined, factor in its size, and select a work envelope accordingly. At a minimum, the work envelope needs to be larger than the largest part being machined. However, depending on production goals, buying a machine with twice the work envelope that supports pendulum processing, where materials are safely loaded/unloaded while the machine is still performing cutting operations on another part, will significantly speed up overall production time. Other advantages of large tables include batch processing which allows you to fixture multiple parts at one time and machine continuously without having to unload and reload.

Note - When searching for 5-axis machining solutions, be sure to consider the work envelope while the machine&#;s spindle is at 90 degrees.

6. A Second Spindle (option) - Doubles the throughput

M-Series Twin Spindle. Watch the Plastic Machining Demo.

A second spindle is valuable when machining small or long composite parts at high volume. Adding a second spindle doubles the machine&#;s throughput without increasing its footprint. Depending on the machine manufacturer, take it a step further by adding up to 8+ spindles for maximum part production.

7. Two Tables (option) - Continuous operation

Similar to a pallet changer for a traditional CNC machine center, a second table allows an operator to load composite material onto, or unload finished parts from, one of the tables while still machining on the other table, so production never has to stop. Additionally, on some machines, two independent tables can be electronically &#;locked&#; together to process extra-large parts.

Dual Process Machining. For High-throughput Production. Watch Video

Dual Process - Combine a multi-spindle option with a multi-table option to unlock the ability to perform what is known as Dual Process machining. With this technology, one spindle performs an operation on one of the tables while the second spindle performs a completely separate operation on the other table, essentially turning one machine into two in the footprint of one machine.

8. Return on Investment - Planning for the long haul

The cost of the CNC machine matters, but more importantly is the return on investment. A cheaper or lesser machine that fails to meet the unique challenges of machining composites and that has to be replaced after only a few years can cost a company more in the long run, not just in direct costs but in lack of part quality, production downtime, program delays, and added frustration. As John Ruskin says, &#;There is hardly anything in the world that some man cannot make a little worse and sell a little cheaper, and the people who consider price only are this man&#;s lawful prey.&#; It is worth the time to work with experts in the field to ensure the machine being purchased is the very best for the specific composites manufacturing application.

9. Support and Service - Questions to ask before buying

C.R. Onsrud Remote Support, Troutman NC.

Asking the right questions provides an understanding of the service and support offered by an original equipment manufacturer (OEM) or dealer. Before making a purchase, some key questions to ask include:

How many dedicated CNC technicians are there (not for other machinery)?
Is there 24/7 support for emergencies?
Is there remote login support?
What is the lead time on replacement parts?
What is the lead time on replacement spindles specifically (in the event of a crash)?
At what point do machine parts become obsolete and are no longer made or carried?
Where is the service department located?
Where are spare machine parts manufactured and/or stored?

10. American Made vs. Imports - Some food for thought

Buying an American-made CNC machine means:

Parts and services for uncommon components can be shipped out ASAP rather than waiting for weeks, or even months, on an overseas shipment.
A heavy-duty, high-quality build is possible vs. a machine that must fit into an overseas container.
American labor laws and manufacturing requirements are followed, ensuring fair and safe conditions and business practices.
Helping to employ U.S. workers and supporting the American economy.
A positive impact on future generations, both job-wise and environmentally.
Promoting American independence.

Want to learn more?

Call a composites machinery expert today.

The company is the world’s best FRP Waste Water Collection Tank supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.