Consulting

Tooling Design

If you are purchasing pultrusion dies from us, die design is included in the cost of the tooling. If you would like to purchase tooling elsewhere we can still provide die design at a cost based upon the desired profile.

Client will provide profile drawings to Abersham for the desired pultruded components, and will be solely responsible for the proper profile design for the intended application.

Abersham will then produce tooling design drawings that will result in the production of profiles of the correct cross sectional dimensions as supplied.

Abersham will supply detailed pultrusion tooling specifications, including the tool steel requirements, tolerances, surface finish, and the coating or case hardening procedure. This is a standard part of our technology package included with the purchase of a complete pultrusion line.

Production Setups

Abersham will design and provide drawings for the pultrusion setups required for each profile to be pultruded. Three profile production setups are included with the purchase of each pultrusion line. This will include the forming guides, resin wet out area, and MACT compliant enclosure. This will be design drawings only for fabrication at your location or we can supply ready to run production setups at an additional cost based upon the profile.

Future additional setups will be an optional purchase item. We can supply design only, or complete ready to run production setups.

Pultrusion Machinery

We will work directly with you in the pultrusion equipment specification to ensure that the production lines purchased will have the proper capacity and be capable of pultruding the intended profiles, and that the machinery will be compliant to USA standards. Abersham will finalize the exact machine specification for approval by both parties, which will include puller size and design, cutoff saw details including automation and enclosures, the required die stand and heating capacity. Machinery recommendation will be according to the intended profiles to be produced.

Reinforcement Delivery

We will supply you with design drawings for the required mat creels and roving racks for each production line based upon the profiles being produced. You may then construct them at your facility, or subcontract them locally. These are large items that take up a lot of shipping space and it is more economical to fabricate them locally.

If you wish, we can supply these pre-fabricated and ship them to your location as well. Pricing based upon profiles to be produced and the needed reinforcement capacity.

Raw Material Recommendations

Abersham will supply you with the recommended resins, catalysts, reinforcements, pigments, and other chemicals required for production as well as a recommended supply for each. We can not be held responsible for production problems encountered due to substitute raw materials.

Production Layout

We will supply you with a recommended pultrusion manufacturing layout which takes into consideration reinforcement delivery area, setup and forming area, size of production lines, cutoff and runout area, profiles being produced, and required forklift lanes for die delivery and removal.

Resin Formulations

Abersham will supply a recommended resin formulation for each profile to be produced to ensure proper processing and profile performance.

Reinforcement Design

Abersham will supply a recommended layout of reinforcements for the profiles to be produced. The design will be recommended to achieve a 50-55% reinforcement by weight ratio of the final profile content which is typical in the pultrusion process for structural components. This will include size and placement of continuous strand fiberglass mats as well as size and placement of continuous unidirectional roving.

Mixing

Requirements for resin mixing, raw material storage, and accepted handling and storage techniques will be supplied. Mixing training to be done in conjunction with startup training.

Mat Slitting

We will provide a recommendation for the type of mat slitter required. We can also provide you with this needed piece of equipment. See our "Mat Slitter" page. Training on mat slitting to be done in conjunction with startup training.

Tooling Maintenance

Abersham will supply the procedures required for die and setup cleaning and required tooling maintenance. We can also provide you with a complete cleaning system. See our "Pultrusion Accessories" page.

Staffing Recommendation

We will provide you with a recommended staffing structure in order to run the specified shifts and volumes of profiles required. Staffing will include tooling maintenance, resin mixing, mat slitting, production setup and operator teams.

Documentation

Pultrusion Operations Manual included with the purchase of any complete pultrusion line. This manual covers all aspects of the pultrusion process in detail.

Production Commissioning Completion

When under our direction, you have successfully produced meaningful quantities of each pultruded profile included in the scope of production, with acceptable scrap ratios not to exceed 10%, the training will be considered complete and successful. We can not be held responsible for excess scrap, reduced production speeds, production and quality problems due to substitute raw materials, or other factors beyond our control. Meaningful quantities shall be defined as 2 days production of each profile at the recommended production speeds. At this time the final commissioning payment will be considered due within 10 days.