5m x 2m AUTOCLAVE 0NE
A high temperature, high pressure 5m by 2m autoclave to develop advanced, complex and high quality prototype and production composite components.  The 350°C autoclave, believed to be one of only a handful in the UK, is ideally suited for developing temperature resistant and low toxicity composites whilst the 200PSI pressure enhances quality even on intricate parts.

2m x 700mm AUTOCLAVE
Our original 2.0m long by 700mm diameter autoclave. Capable of 100psi and temperatures over 200°C, with an additional vacuum pump, it is electronically monitored and controlled offering a 24/7 operating cycle. A Sanjo Gallenkemp OMT oven with a 150 litre capacity and temperature range up to 260°C provides post curing ability for mould durability.

Fitting room
Fully equipped room offers ability to assemble using fixtures or bonding methods. Long experience in harsh environments means BERU f1systems can offer robust joining solutions whatever the application.

Trim room
Dedicated to trimming carbon components to their final state, the room is equipped with a full extraction system and air conditioning. A down draft bench has recently been installed so components can be trimmed with little or no mess. A band saw, belt sander and pillar drill ensure all final finishing can be completed in house - rapidly.

machining centre
Our new in house machining centre offers the capability to manufacture tooling and moulds for composites tooling.  Fur further details on our machining centre, please click here.

Case Studies
Recent applications where BERU f1systems made a difference:

Composites offer significant weight reduction
BERU f1systems composites division has commenced production composite air boxes for a leading induction specialist. Using expertise from other programmes, the team at BERU f1systems paid particular attention to the lay up process as the key method for reducing weight. The result achieved was significant, the final version being some 11.5% lighter. With air filters tending to be mounted higher up in the engine bay, this also helps to lower the centre of gravity. The lay up process used also ensured the inner surfaces were smooth to minimise airflow disruption, enhancing performance.

Composites provide solution when original tooling is no longer available
When OE tooling is no longer accessible, damaged or worn, BERU f1systems can offer reproduction components in composite eliminating the high investment cost that high volume tooling is normally associated with. Using an original component BERU f1systems offered the client laser analysis to reproduce the component or as finally selected in this example a glass fibre mould was created to form a pattern. To prevent damage to the rare OE part a specific curing technique was adopted. BERU f1systems was able to offer the client a durable lacquered finish to prevent deterioration due to light exposure.

Critical Tolerances in hot environment require accurate moulding with heat reflective capabilities.
To achieve maximum race performance strict tolerances were necessary for an engine airbox. The product required absolute accuracy with CMM being used throughout the mould development. As well as the tight tolerances the component required bushes laminated in the material. With the structural integrity critical to ensure the tolerances were achieved, even during use, a Nomex core sandwich was developed for the structural elements and bush insertion points. As a further challenge, the client required a solution to minimize the air flowing through the structure to become heated. BERU f1systems selected a silvered aluminised aluminium carbon for the outer layer. The silver finish offered an additional aesthetic benefit to the client providing a key differentiation to competitor offerings.

For more information contact BERU f1systems or email Composites. Alternatively phone +44 (0) 1379 646219 to speak to a specialist right away.