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Items & Technology

MaruHachi is making efforts to provide clients with optimal Reinforcements, Prepreg materials, Preform materials and Solutions.
Utilising material processing technology and evaluation & analysis capabilities built on composites engineering-based theory & experience, and backed up by CAE as computational science and other peripheral technology such as joining and bonding technologies.

01.Reinforcements
02.Prepreg Material
03.Preform Material
04.Secondary Process

01Reinforcements

They are reinforcements made from high-performance fibres and manufactured using the weaving and knitting technologies developed by the Maruhachi Group.
These reinforcements include biaxial, unidirectional (UD) and three-dimensionally structured.

Materials

Carbon fiber

Aramide fiber

High-strength polyethyrlene fiber

Liquid crystalline polymer fiber and others

Technology

Warp Knitting Fabric

Warp knitting is a knitting technique whereby fibres are looped together in a vertical direction to produce a Reinforcements.
Warp knitting is a generic term for a knitting technique that produces a reinforcement with a constant width by using hundreds to thousands of fibres in a horizontal line.

Single russell fabric
UD90 russell fabric
stich bonding fabric
double russell fabric

Single russell fabric

Single russell fabric

Russell fabric is a knitting technique that uses fibres with a relatively high counts in warp knitting and is superior for coarse knitted fabrics.　
Single russell fabric is a reinforcement with a knitted surface on only one side.

Specifications: Width (mm) up to 3,300
Length (M) up to 500
Take-up diameter(mm) 1,500 max.

UD90 russell fabric

UD90 russell fabric

90° UD Russell fabric is a reinforcement in which the reinforcing fibres are arranged in a straight line only in the 90° direction and the fibres are gripped by the Russell knitting.　
The performance of the high-strength fibres is only demonstrated in the 90° direction, while the overall shape-following properties of the knitted fabric have excellent draping properties.

Specifications: Width (mm) up to 3,200
Length (M) up to 500
Take-up diameter(mm) 400 max.

stich bonding fabric

stich bonding fabric

This knitted reinforcement unites different sheet materials by stitch knitting using warp knitting technology.
It is suitable for sandwich construction materials using materials with different properties in the front, back and inner layers.

Specifications: Width (mm) up to 2,100
Length (M) up to 500
Take-up diameter(mm) 800 max.

double russell fabric

double russell fabric

Russell fabric is a knitting technique that uses fibres with a relatively high counts in warp knitting and is superior for coarse knitted fabrics.　
Double russell fabric has a three-sided structure (one side x middle side x one side), resulting in a base material with a three-dimensional structure.

Specifications: Width (mm) up to 2,400
Length (M) up to 500
Take-up diameter(mm) 800 max.

Technology

Woven Fabric

Weaving is a technique for producing textiles by crossing fibres vertically and horizontally.
It is a generic term for weaving technology that uses hundreds to thousands of fibres in a horizontal line to produce a reinforcement with a fixed width.

Standard woven fabric

Standard woven fabric

Biaxial reinforcement with 0° and 90° weave structure using weaving technology. It is manufactured as a standard woven fabric using carbon fiber regular tow to large tow.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

UD 0 woven fabric

UD 0 woven fabric

Uniaxial reinforcement with a weave structure of 0° using weaving technology.
Manufactured as standard woven fabric using regular to large tows of carbon fibre.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

UD 90 woven fabric

UD 90 woven fabric

Uniaxial reinforcement with a weave structure of 90° using weaving technology.
Manufactured as standard woven fabric using regular to large tows of carbon fibre.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

Hybrid woven fabric

Hybrid woven fabric

Hybrid woven fabric made by combining carbon fibres, aramid fibres, glass fibres and other high-strength fibres according to various specifications and applications.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

Thin layer spread woven fabric

Thin layer spread woven fabric

The term 'spreading' is used to describe the process by which high-performance fibres are spread into individual fibres in a fibre bundle using a number of suitable techniques and arranged side-by-side in the fibre bundle.
The fibre bundle shape is thereby changed from circular to flat, and textiles woven using these fibres can be made thinner than those made from normal fibres.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

Tape woven fabric

Tape woven fabric

Sheet materials are slit into tape and woven to produce tape woven fabric.
This is effective for materials with directional properties, or when draping properties are required that cannot be achieved in sheet form.

Specifications: Width (mm) up to 1,000
Length (M) up to 200
Take-up diameter(mm) 500 max.

02Prepreg Material

The term prepreg is derived from Pre-Impregnation.
Thus, PPG (prepreg) material is a moulding material in which a reinforcement is impregnated with a matrix resin.
It is a moulding material with high performance by aiming for a synergistic effect through the effective combination of fibres and resin.
MaruHachi also uses the term PPG material as a generic term for processed products using resins, such as coating materials.

Reinforce Fibers

Carbon fiber

Aramide fiber

High-strength polyethyrlene fiber

Liquid crystalline polymer fiber and others

Matrix Resin Sytem: Thermosetting type

Epoxy, etc

Thermoplastic type

Middle MT rabge PA6,PC,TPU,etc

High MT range LCP,PPS,PEEK,etc

Technology

Thermo Setting Prepreg

MaruHachi formulates the matrix resins used in thermoset PPG in-house.
This makes it possible to add functionality to thermoset PPG in accordance with the application, in addition to the high strength, high rigidity and light weight required of thermoset PPG.
In addition, it is possible to select from a range of reinforcements, including unidirectional (UD), biaxial fabric and random materials, to suit the application and moulding process.

Matrix resin formulations
UD TS Prepreg
Woven fabric TS Prepreg
Random TS Prepreg

Matrix resin formulations

Matrix resin formulations: MaruHachi formulate and mix thermosetting matrix resins, mainly epoxy resins.　Combinations of the main resin with hardeners, additives, filler materials, etc., enable the appropriate functionality to be expressed.

UD TS Prepreg

UD TS Prepreg

This is a sheet-type composite material made of high-performance fiber orientated vertically within a predetermined width range and impregnated with a matrix resin.

Specifications: Width （mm） up to 1,000
FAW, RC, Vf are available in a wide range of configurations.

Woven fabric TS Prepreg

Woven fabric TS Prepreg

Sheet-type composite material made by impregnating a fabric type reinforcement with a matrix resin.

Specifications: Width （mm） up to 1,000
FAW, RC, Vf are available in a wide range of configurations.

Random TS Prepreg

Random TS Prepreg

Sheet-type composite material made of random distributed reinforcement impregnated with matrix resin.

Specifications: Width （mm） up to 1,000
FAW, RC, Vf are available in a wide range of configurations.

Technology

Thermoplastic Prepreg

These prepreg materials are made from thermoplastic resin as the matrix resin. Unidirectional (UD), fabric and random reinforcements can be selected to suit the application and molding process.
Environmentally friendly material in terms of recycling and re-use.

UD TP Prepreg
Woven fabric TP Prepreg
Random TP Prepreg

UD TP Prepreg

UD TP Prepreg

This is a sheet-type composite material made of high-performance fiber orientated vertically within a predetermined width range and impregnated with a matrix resin.

Specifications: 【Middle MP type】
Width (mm) up to 1,000
FAW, RC, Vf are available in a wide range of configurations.

【High MP type】
Width (mm) up to 500
FAW, RC, Vf are available in a wide range of configurations.

Woven fabric TP Prepreg

Woven fabric TP Prepreg

Sheet-type composite material made by impregnating a fabric type reinforcement with a matrix resin.

Specifications: Middle MP type
Width (mm) up to 1,300
Length(mm) up to 1,300
FAW, RC, Vf are available in a wide range of configurations.

High MP type
Width (mm) up to 500
Length (mm) up to 500
FAW, RC, Vf are available in a wide range of configurations.

Random TP Prepreg

Random TP Prepreg

Sheet-type composite material made of random distributed reinforcement impregnated with matrix resin.

Specifications: 【Middle MP type】
Width (mm) up to 1,300
Length(mm) up to 1,300
FAW, RC, Vf are available in a wide range of configurations.

【High MP type】
Width (mm) up to 500
Length (mm) up to 500
FAW, RC, Vf are available in a wide range of configurations.

Technology

Resin Coated Materials

Water-based coating processes are used to stabilise the shape and add functions to reinforcements such as fabrics, and non-woven.
Since 2004, MaruHachi has been preparing solvent-free production lines for these processes from the perspective of environmental friendliness.

Hotmelt coating
Water based coating

Hotmelt coating

Hotmelt coating

MaruHachi offers coated sheets that meet the needs by means of processing methods that suit the application and purpose, such as curtain spray coating for air permeability and film coating for waterproofing, starting from the manufacture of reinforcement as required.
A wide range of materials are available, including polyolefin, polyamide and polyester.
Bonding and slit tape processing are also available for these sheet materials.

Specifications: Width (mm) up to 1,000
Length (M) up to 500
Take-up diameter(mm) 1,000 max.

Water based coating

Water based coating

The company manufactures coatings materials that meet the needs of its customers by means of coating agents and processing methods that are suitable for the application and purpose.
Bonding and slit-tape processing of these reinforcements are also carried out.

Specifications: Width (mm) up to 1,000
Length (M) up to 500
Take-up diameter(mm) 1,000 max.

03Preform Material

Preform materials are processed by using reinforcement and PPG materials. Laminates as intermediate materials and easyform profile and pipes as semi finished parts

Technology

Full Automation Layup System with Insprction System

Large-scale laminate forming and processing, as well as non-destructive testing, can be carried out using a combination of angle cutting and joining equipment, automatic laminating equipment, multi-stage presses and C-scans.

Laminates

Laminates

Laminates

First, prepreg sheets are cut and joined at the set angle to create angle materials, which are then laminated in any desired layup structure. This system can mass-produce laminates up to 1,300mm square by simultaneously laminating and inspecting multiple sheets.

Inspection can be carried out on large laminates up to 1,300mm square using C-scan and ultrasonic thickness gauges without destroying the laminate.

Specifications: Processing size：1,300×1,300mm(max)
Layup angle：0/90/-30/30/-45/45°

Technology

Press Molding

With 30t/200t/500t single presses, we have abilities for laminates and performs processing.

Laminates
Simple sahpe molding

Laminates

Laminates

Beside composite laminates processing, recycled material pellets, foams are available for processing

Specifications: zprocessing size：500×500mm

Simple sahpe molding

Simple sahpe molding

As a intermedia profile, it is possible to form simple shapes with a height (depth) of up to about 50mm.

Specifications: RFA

Technology

Filament Wind Molding

Matrix resin-impregnated strands are wounded on a mandrel to form a tanks or pipe shape.

CFRP High-pressure cylinder
Thermo setting Pipe profiles

CFRP High-pressure cylinder

CFRP High-pressure cylinder

These are containers designed to maintain airtightness of gases or liquids at extremely high pressures, such as 700 atmospheres (70 MPa) in MEOP.
They are used in hydrogen storage containers and rocket fuel tanks, etc.

Specifications: Processing size：Φ550 x L1,500 mm(max)

Thermo setting Pipe profiles

Thermo setting Pipe profiles

Cylindrical in shape, such as pipes, and used as piping and structural materials.

Specifications: Max ID：550mm
Min ID：10mm
Max Length：1,500mm

Technology

AFP Layup

This is a processing technology that uses an AFP head attached to a robot and prepreg tape to perform tape lay-up.
Heating is carried out using a laser method, and stable processing quality is ensured by controlling it with an infrared sensor.

Tailored blank

Tailored blank

Tailored blank

Lay-up can be done directly on the X-Y table to create shapes, or partial lay-up can be done to reinforce plate-like materials.

Although CFRTP is an expensive material, it is possible to use the minimum amount of material required to achieve maximum strength through simulation.

Specifications: Processing size：1,000×2,000mm

04Secondary Process

This is a process for processing the various materials made in the reinforcement, PPG (prepreg) and PF (preform) processes into the shape and condition required by the customer.

Technology

Water-Jet Cutting

We generate and spray ultra-high-pressure water that exceeds the speed of sound, and cut materials with the abrasive particles mixed in.
It is possible to cut and process materials of all kinds, and at our company, we have achieved high-precision, high-quality processing of CFRTP, which is particularly difficult to machine, by adopting an algorithm specialized for this.

Technology

Slitting

This is a process for making tapes by narrow slitting.
The process is selected from several types of cutting methods to suit the product.

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