CAPABILITIES

CAD, FEA Analysis & Engineering

Rockman Advanced Composites is a one stop solution provider for all the advanced composites needs of the customer ensuring wide range of products, technologies and turnkey solutions. We work with customer from initial design concept, product development including material selection, prototyping, testing & then taking the product into mass production.

We have purpose built design & development center with in house expertise of FEA Analysis, tooling designing, material Selection, laminate designing, Jig /Fixtures designing & range of composites manufacturing

techniques. We manage smooth transition of newly designed product / manufacturing process to our in-house prototyping shop and then our mass production. Availability of in-house machining / manufacturing facility allows our designers to have more practical manufacturing approach to the designs / process documents.

Description

We have purpose built design & development centre with in house expertise of FEA Analysis, tooling designing, material Selection, laminate designing, Jig /Fixtures designing & range of composites manufacturing techniques. We manage smooth transition of newly designed product / manufacturing process to our in-house prototyping shop and then our mass production. Availability of in-house machining / manufacturing facility allows our designers to have more practical manufacturing approach to the designs / process documents.

Capabilities

    • Catia V5 for product and tooling design
    • Full capable Class A surfacing
    • FEA
    • Laminate analysis & material selection.

Facilities

  • Catia V5,
  • Autodesk Powershape,
  • Powermill
  • Powerinspect
  • Polyworks
  • Cadbro

Tooling, Jig & Component Machining

We have capabilities of designing, programming & machining of patterns, moulds & jigs made out of epoxy tooling blocks / aluminium / wood, machining of core materials & composites parts etc.

We have purpose built tooling & machining facilities which caters needs of tooling manufacturing & high precision trimming of composites parts. We have 5 Axis machines with working envelopes up to L 3.6m x W 1.8m x H 1.2m, 4 Axis machines with working envelopes up to L 0.762m x W 0.406 x H 0.508m, 3 Axis machines with working envelopes up to L 4m x

W 1.5m x H 0.4m & CNC Turning lathers with working dimensions up to Dia 0.264m x L 0.375m. These machines are capable of machining epoxy tooling, wood, aluminium, core materials, glass / carbon composites components.

Description

We have purpose built tooling & machining facilities which caters needs of tooling manufacturing & high precision trimming of composites parts. We have 5 Axis machines with working envelopes up to L 3.6m x W 1.8m x H 1.2m, 4 Axis machines with working envelopes up to L 0.762m x W 0.406 x H 0.508m, 3 Axis machines with working envelopes up to L 4m x W 1.5m x H 0.4m & CNC Turning lathers with working dimensions up to Dia 0.264m x L 0.375m. These machines are capable of machining epoxy tooling, wood, aluminium, core materials, glass / carbon composites components.

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Capabilities

  • Machining of
  • Patterns
  • Moulds
  • Jigs
  • Composite Components
  • Using Materials
  • Epoxy Tooling Boards ( In-house )
  • MDF ( In-house )
  • Aluminium ( In-house )
  • SS & Invar ( from approved vendors )

Facilities

  • 2x 5 Axis Machine Working envelope L 3.6m x W 1.8m x H 1.2m
  • 2x 4 Axis machines Working envelopes L 0.7m x W 0.4m x H 0.5m
  • 1x 3 Axis machines Working envelope L 4m x W 1.5m x H 0.4m
  • 2x CNC turning lathe Dia. 0.26m x L 0.37m

Composites Parts & Moulds Manufacturing

We have expertise in manufacturing moulds made up of carbon fiber prepregs & parts made up of Carbon, Glass, Kevlar, Hybrid prepregs & various types of Sandwich panels made up of rohacells, honeycomb, balsa wood, aramid core etc.

  • Carbon fibre / epoxy Prepreg based moulds
  • Also “direct” moulds in
  • MDF
  • Epoxy Tooling Board
  • Aluminium
  • SS
  • Invar

Description

We have purpose built facility with,

  • Dedicated class 8 cleanroom, various laminating rooms
  • Cool rooms maintained at -18 deg C
  • Prepreg cutting machines with bed size up to 1.3 X 2.5 m
  • Various autoclaves with maximum working diameter of 1.5m / length of 4.5m
  • Programmable Owens with maximum working envelope being of 3m x 2m x 6m
  • Dedicated trimming, assembly, bonding areas with vapourmatt wet blasting machine
  • CNC machines for part trimming/machining/ holes drilling activities.
  • We have worked in wide variety of Carbon, Glass, Kevlar, Hybrid prepregs with variety of resin system

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Manufacturing Capabilities using various prepreg

  • Woven / UD Carbon*
  • Forged Carbon
  • Woven / UD Glass
  • Colour pigmented Glass
  • Hybrid prepreg– Carbon Kevlar, Carbon Glass, Glass Kevlar
  • (*High Strength, Intermediate Very High Strength and High Modulus)

Sandwich construction using

  • Polymethacrylimide (PMI)
  • Ployvinyl chloride (PVC)
  • Polyethelene Teraphalate (PET)
  • Balsa
  • Honeycomb – Aramid / Aluminium
  • Cork

Assembly using adhesives & mechanical fastening

  • Composites to composites
  • Composites to metal ( Aluminium / SS )
  • Composites with 3D printed parts

Assembly using co-curing

  • Composites to composites
  • Composites with metal ( Aluminium / SS )
  • Composites with 3D printed parts
  • Composites with rubber
  • Composites with Polyvinylidene fluoride ( PVDF )

Facilities

  • 1x Prepreg cutting machine. Bed Size: 1.3 X 2.5 m
  • 3x freezer with total 12000 sq.m Prepreg storage capacity (at -18°C)
  • 3x Autoclaves with max. working diameter of 1.5m / length of 4.5m
  • 2x programmable ovens with max. working envelope being of 3m x 2m
    x 6m
  • Class 8 cleanroom & various laminating rooms

QUALITY MANAGEMENT

Quality is massively important and we aim to provide all our customers with products and services that meet or even exceed their requirements. We are ISO 9001:2015 & AS9100-D certified. We have also undergone numerous Automotive / Aerospace / Defence / Railway OEMs audits & successfully cleared / registered with them.

Description

We have dedicated QC area equipped with surface tables & 7 Axis FARO arm laser scanner fitted with touch probe and also machine verification by touch probe on CNC machines. With our QMS- Quality Management System & QR code controlled ERP system, we can carefully control the processes of the product lifecycle like traceability of materials, product configuration, process flow, in process / final quality etc of all the tooling’s, jigs & all the components manufactured by us. We are committed and continue to deliver the highest quality products and services to all of our customers.

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LOGISTICS

We work with world’s leading logistic companies for road, sea & air shipments. Major part of our shipments is done via air shipment with delivery to customer place in US or Europe in a weeks’ time in a most cost effective way.

Description

Currently we are running between 2 and 3 regular shipments per week to UK / US / Europe. Shipping times are typically 7-10 days in a regular air shipment. Express air shipment is possible in 3-4 days. Large components supported, complete SUV racing series bodywork supplied from India by air shipment. Shipment by sea usually takes 30-45 days & large heavy volume parts are shipped by sea.

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