Composite doctor blade body

hanno stimolato la creatività del team di R&D Fibercompositi che ha raccolto la sfida, e, brevettando un nuovo sistema di produzione, ha permesso di soddisfare ogni esigenza contenendo i costi. Ogni nuova richiesta di sviluppo di tali componenti inizia con la fase di progettazione e analisi FEM che ci consente di identificare il giusto rapporto tra la riduzione del peso e la rigidità: tipicamente con una riduzione del 35-40% del peso rispetto allo stesso componente in alluminio, siamo in grado di ottenere una rigidezza superiore del 15-20%. Successivamente in collaborazione con il cliente studiamo la migliore soluzione possibile rispettando la geometria originale ed eventualmente adattando il pezzo ai vari componenti dell’assieme finale e predisponiamo tutti gli inserti per il montaggio in acciaio inox per garantire la resistenza alla corrosione. Questa fase di studio precede la progettazione e realizzazione delle attrezzature necessarie all’ottenimento del pezzo. Grazie alla nostra tecnologia di produzione la camera inchiostratrice è ottenuta di stampaggio evitando quindi lavorazioni di asportazione che, facendo affiorare le fibre, ne potrebbero pregiudicare l’impermeabilità con la conseguenza di contaminazione dell’inchiostro. Normalmente siamo anche in grado di regolare

ENGLISH Version Composite doctor blade body

FIBERCOMPOSITI WAS BORN IN THE EIGHTIES AS A SUPPLIER OF COMPOSITE MATERIAL COMPONENTS FOR THE TEXTILE MACHINERY INDUSTRY, RESPONDING TO THE NEEDS OF FRAME BUILDERS LOOKING FOR INNOVATIVE SOLUTIONS TO OVERCOME THE LIMITS OF LIGHT ALLOY PRODUCTS. OVER THE YEARS, TECHNICAL AND TECHNOLOGICAL DEVELOPMENT HAS ALLOWED THE COMPANY TO OPEN UP TO NEW MARKETS, INCLUDING FLEXO SECTOR

Composite materials are used instead of metallic ones, where it is necessary to improve static and dynamic performances and resistance to corrosion; further benefit is the reduction of mass which involves less inertia and greater handling. Fibercompositi has been producing carbon fiber rollers and cylinders for some years, supplying the major European manufacturers of flexo machines. The frequent contacts between the various R&D teams have been fertile ground for the growth of new proposals and ideas concerning the development of the doctor blade holder. We immediately understood the need of each single partner to create a replacement and interchangeable component with all the already existing parts, thus also respecting the doctor blade geometries which are the “trademark” of each manufacturer. Starting from this base, Fibercompositi R&D department had to search for a solution for the production of the piece, focusing on innovative methods and technologies that would allow the creation of a “tailor-made” carbon fiber doctor blade body chamber, allowing, for example, to use their own blade-holding closing systems, loading/unloading/washing systems, machine locks, etc. The economic advantages for the customer of not having to redesign and possibly produce “ex novo” all these components on new machines are added to the possibility of being able to retrofit already installed machines without additional assistance costs, whose users need an increase of

l’eventuale pre-curvatura longitudinale del corpo racla soddisfacendo le specifiche di settaggio a bordo macchina. Tale peculiarità trova notevole riscontro nei casi di tavole molto grandi consentendo di mantenere le pressioni di esercizio contenute. La resina che utilizziamo è stata testata per valutarne la resistenza ai maggiori solventi e ai primer impiegati nell’industria della stampa, e, grazie ai risultati ottenuti, equipaggiamo anche macchine per la stampa digitale sostituendo i particolari in alluminio o tecnopolimero la cui corrosione e poca rigidità ne limitano l’utilizzo. Volontà, impegno, flessibilità e innovazioni tecnologiche sono la risposta di Fibercompositi alle esigenze del mercato flexo. 

performance. So far everything is normal... but... when it comes to carbon fiber products, moreover personalized, one of the recurring objections is “too expensive!”, consequently another of the main inputs was the containment of the cost of the product. These premises stimulated the creativity of Fibercompositi R&D team that took up the challenge, and, by patenting a new production system, made it possible to satisfy every need while containing costs. Each new request for the development of these components begins with the design and FEM analysis phase that allows us to identify the right relationship between weight reduction and stiffness: typically with a 35-40% weight reduction compared to the same component in aluminum, we are able to obtain a higher stiffness of 15-20%. Subsequently, in collaboration with the customer, we study the best possible solution respecting the original geometry and possibly adapting the piece to the various components of the final assembly and we prepare all the inserts for assembly in stainless steel to ensure resistance to corrosion. This study phase precedes the design and construction of the equipment necessary to obtain the piece. Thanks to our production technology, the inking chamber is obtained by moulding, thus avoiding removal processes which, by making the fibers emerge, could compromise their impermeability with the consequence of ink contamination. Normally we are also able to adjust any longitudinal pre-curvature of the doctor blade body, satisfying the setting specifications on the machine. This peculiarity finds considerable confirmation in the case of very large tables, allowing to keep contained operating pressures. The resin we use has been tested to evaluate its resistance to the major solvents and primers used in the printing industry, and, thanks to the results obtained, we also equip digital printing machines by replacing the aluminum or technopolymer parts whose corrosion and low rigidity limit their use. Willpower, commitment, flexibility and technological innovations are Fibercompositi’s answer to the needs of the flexo market.