Used for manufacturing of various thermoplastic sheet products using heat to soften it and then forming in a mold. FCI operates a state of the art continuous thermoforming machine that has a forming table size of 8’ x 4’. Continuous forming allows us to produce more than 4000 sheets per day to fulfill demanding requirement of our clients.
Mainly FCI utilizes the thermoforming process for the manufacturing of in fill material for Cooling Towers. We have a range of designs readily available and can also manufacture any new design within 2 weeks. FCI ensures that up to date equipment and prime materials are used for stringent industrial applications. Due to our control on all phases of the process ranging from mold design, mold making, manufacturing and installation, we can provide our clients with unmatched services.
Sheet molding compound (SMC) is a fiber reinforced thermoset resin compression molding process used for manufacturing of high strength composite parts. SMC is used where large volumes of parts are required which exceptional aesthetics and mechanical characteristics. The process uses a specially formulated fiber / resin compound which is placed in heated molds and pressed using high pressure compression molding machines. As the parts is removed, it is cured and ready to use.
Use of SMC has become widely popular due to quick cycle times and low manufacturing costs for high volume productions. FCI has been producing SMC products since more than a decade. FCI has been producing parts ranging from small parts of a few grams to large parts weighing more than 30 kg per part. However, higher capacity parts can be produced and our design / manufacturing team is always available to fulfill any customized requirement of our clients.
Resin Transfer molding commonly called RTM in the composite industry is synonymous to injection molding technique used for the processing of thermoplastic parts. RTM is a closed mold process which provides exceptional dimensional control and repeatability in addition to product finishing on all sides.
However, use of RTM has been limited in our market due to its inherent upfront cost as the mold has to be machined in metal. RTM uses high pressure resin injection in the mold where the fibers are preplaced before closing the mold. FCI has been operating RTM since more than last 15 years and has extensive experience in manufacturing of any complex shape. Our in-house mold making process gives us further flexibility and confidence to provide our clients with minimum lead times.
Conventional contact molding processes are widely used for fabrication of composite products. Although, contact molding processes provides substantial flexibility in producing complex shapes and moldings. However, it lacks uniformity in product as a result of non-uniform resin distribution. Vacuum infusion process uses vacuum to drive resin into the laminate. Vacuum infusion allows to have uniform resin distribution in the end product and thus almost uniform product thickness. The product uniformity allows for homogenous mechanical properties and repeatability in manufacturing.
FCI has diverse experience in producing parts from vacuum infusion process using both glass and carbon fibers. The only limitation is that the product has one side finished / gel coated surface as in the case of contact molding. To date FCI has produced parts as huge as 40 ft in length using Vacuum infusion technique. However, this limitation can be further overcome by shifting to a much more robust Resin Transfer Molding Process.
Precision manufacturing of composite parts require utmost control and dimensional accuracy at the time of pattern / plug and subsequent mold making. Conventionally such patterns / plugs were made using traditional carpentry tools. However, to cater the ever increasing demand of dimensional accuracy in advanced composite parts, precision machining processes have been incorporated in the production facility to ensure that up to date production practices are followed and manufacturing of up to the mark parts at par with Global manufacturing standards can be produced.
We are proud of being the first and currently the only local private sector facility to have installed such advanced machining facilities. FCI has multiple machines from small bed size of 8’ x 4’ up to large scale machines that can machine parts of up to 36’ x 12’ x 5’ (y,x,z). Machining of complex intricate shapes is not a limitation anymore and any design can be transferred from drawing to product in a matter of few days. Our competent design & manufacturing team can transform any idea from the client end in to a physical product with pin point accuracy.
Pipes & tanks are lifeline of any production facility, infrastructure or public health project. FCI has two state of the art Filament Winding machines that can produce pipes from as small as 25 mm in diameter up to 4000 mm / 4 m diameter and factory built tanks having capacity of up to 40,000 gallons with utmost accuracy. Computer Numeric Control allows us to produce exactly identical product each time providing repeatable and quality product. The machines are capable to produce parts as long as 13 meters.
FCI is the pioneer and leader in the industry in manufacturing of filament wound fiberglass pressure pipes and storage tanks. Our filament winding machines facility is further reinforced by a range of grinding & molding machines that gives us complete control in providing any kind of fittings and joints. Our robust and state of the art equipment coupled with highly experienced and dedicated staff allows us to provide our customers with products having a leading market warranty and long lasting operational performance.
Used for manufacturing of uniform cross section fiberglass structural shapes. Currently, FCI is operating 5 pultrusion lines to cater for the ever increasing demand of non-metallic structural members for multifarious industrial applications. While, on one hand inherent electrical resistant properties of fiberglass makes it a suitable candidate for life saving electrical safety items and on the other hand, growing awareness towards the use of non-metallic structural members in highly corrosive plant environments have resulted in a major shift towards long lasting and sustainable products pushing a more swift shift towards composites.
FCI has in stock more than 150 different pultrusion dies which gives our clients the flexibility to choose from a range of versatile shapes. Other than that we have a dedicated machine shop comprising of multiple different equipment ranging from conventional to CNC machines which allows us to produce any complex die within a few days further providing our client the peace of mind with a one window technical solution.
Contact molding is the most basic and the most abundantly used composite manufacturing technique. Contact molding process is used both for the manufacturing of large scale composite molds and subsequent production. Flexibility associated with the process for manufacturing of complex shapes associated with quick learning and training makes contact molding the most important and widely used technique in composite industry. The contact molding process involves placement of fiber layers and wetting with resin, the process is repeated until the desired thickness is achieved.
Although contact molding process seems quite simple in definition but the most important aspect associated with it is the need for extra-ordinary and quality human resource that is the back bone of the process. Due to human-centric process, product quality depends upon the operator and FCI is proud of being the employer of choice within the country. We have the largest pool of skilled laminators and workers who have been associated with the company since decades and are also provided routine trainings to up lift their capability.
