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leaders in sandwich composite solutions
The two boats that Ericsson entered in the 2008/2009 Volvo Round the World Race make extensive use of sandwich composite technology.
leaders in sandwich composite solutions
Providing SolutionsDIAB is a world leader in the provision of innovative sandwich composite solutions that make customers’ products light, strong and competitive.
DIAB’s solutions include a complete range of high performance core materials, cost effective kits and a comprehensive range of engineering and process support services.
Worldwide Supply & SupportDIAB has manufacturing facilities on four continents and three research and development centers. In order to offer close support to its global customer base DIAB has 18 operating subsidiaries and strategically located distributors around the world.
A Technology LeaderDIAB has been at the leading edge of composite core material development for over fifty years. In particular it has pioneered the use of the sandwich concept to make structures that are significantly lighter and stronger than those made from steel, aluminum and wood.
The company has been very much the technology leader in its field. DIAB was instrumental in introducing core kits to enable its customers to speed fabrica-tion, improve quality, reduce inventory levels and cut waste.
Optimizing the Usage of Sandwich CompositesIt has also been in the vanguard of new environment-friendly developments such as the widely used DIAB Core Infusion™ process. This process brings together all the benefits of sandwich composites with the pro-cessing, performance and health and safety advantages of closed molding.
Making products lighter, stronger and more competitive
the sandwich concept
The Sandwich ConceptIn principle a sandwich consists of two high strength skins or facings separated by a core material. The skins take up the bending stresses and give the structure a hard wearing surface. The light DIAB core material absorbs the shear stresses generated by loads, distrib-uting them over a larger area.
Light & StrongCompared to monolithic composite laminates, alumi-num or steel, the sandwich concept significantly re-duces weight and increases stiffness while maintaining strength. Even higher strength and stiffness properties can be achieved by increasing the thickness of the core without a weight penalty. The higher stiffness can also allow the supporting structure to be reduced thereby enabling further weight reductions.
Freedom of Design Sandwich composites give designers and engineers tremendous freedom in terms of both form and func-
DIAB structural cores and composite sandwich solutions reduce weight while maintaining or improving strength
tion. Compound curves can be readily incorporated. Also, as the outer skins can be accurately aligned to the load paths, structural integrity and performance can be maximized.
Excellent Strength to Weight RatioThe excellent strength-to-weight ratio of the sandwich concept can be used in a variety of ways - higher speeds, longer range, greater payload capacity or reduced power demand – all of which give better operating economy. DIAB sandwich composites also offer good dynamic strength, low water absorption and excellent insulation. Furthermore they require minimum maintenance and repairs can often be carried out easily without any loss of structural integrity.
Cost EffectiveComponents can be readily manufactured using low cost tooling. In addition a wide variety of processes can be used including hand and spray laminating, vacuum consolidation, press molding and resin infusion.
Skin
Bondline
DIAB Core
Stiffness
Weight
Monolithic Laminate
Sandwich
Sandwich
All laminates areof equal strength.
Wind EnergyThe wind energy market was quick to recognize the benefits of using sandwich technology for not just the blades but also the housings and spinners. Today DIAB is working closely with the leading producers regarding the next generation of wind turbines.
As wind turbines have become larger - 40 meter (130 ft.) blades are now commonplace - the role of sandwich cores has become more and more important as they improve the blade’s structural performance without adding weight.
DIAB has been a leading supplier of sandwich cores to the wind energy industry since the mid 1980’s and now over 100,000 DIAB-cored blades are in service.
MarineIn the marine field the sandwich approach is very much the ‘de facto’ standard with hundreds of thousands of boats being built with DIAB cores. Pleasure craft, work boats, ferries and military vessels rely on DIAB sandwich cores to achieve new levels of performance
our markets
DIAB sandwich cores and technology are used wherever and whenever there is a need for low weight, high performance structures
in terms of speed, strength, comfort, reliability and longevity.
Sandwich composites, with their excellent fatigue and slamming properties, are particularly ideal for rescue craft, coast guard vessels and other para-military craft that have to operate in high sea states.
TransportationThe DIAB sandwich concept is one of the best ways to reduce weight in trains, trams, and buses, whether it is used for structural members or paneling. DIAB cores also increase stiffness and provide excellent sound/thermal insulation properties thus eliminating the need for subsidiary materials that add weight. This further weight reduction results in even lower energy consumption and consequently a much lower environmental impact.
IndustryThe industrial use of DIAB sandwich composites covers everything from large buildings through to tanks and even furniture and sculptures. Again the formability,
lightweight and corrosion resistant features of sandwich come to the fore.
Architects and civil engineers are also using sandwich composites for applications where a high strength, lightweight and durable solution is required. Domes, bridges and claddings are just a few of the applications where DIAB sandwich cores are providing exceptional performance. Moreover, with their ability to be produced in complex shapes as single components, sandwich composites give architects full creative freedom.
AerospaceDIAB core materials are also used extensively by vir-tually all sectors of the aerospace industry. In addition to its Divinycell HT grade, DIAB has also developed Divinycell F which is specifically for commercial aircraft interiors.
Executive jets also feature lightweight DIAB cored paneling for the interiors and military aircraft use DIAB composites for both structural and non-structural ap-plications.
Vestas, the world’s largest wind turbine manufacturer, uses DIAB sandwich cores in the blades, nacelles and spinners.
a combination of products With its integrated range of products and services, DIAB can partner its customers through every facet of the composite design and manufacturing process in order to improve component performance/quality, reduce
moulding times and cut material costs.
The Most Extensive RangeIts Divinycell range is undoubtedly the most compre-hensive available allowing designers, engineers and fabricators to choose the right core material for their
specific application.
In addition to its general purpose Divinycell H grade and pre-preg compatible Divinycell HP, the company produces grades that have been developed to suit specific application areas. These include Divinycell P which has been designed for land transportation and construction applications and Divinycell F - the aircraft interiors core. The company also produces ProBalsa end-grain balsa core.
The Widest Range of FinishesAll DIAB cores can be supplied with the widest range of finishes available in the industry. The aim is to facilitate and speed core installation, enhance component qual-ity and to meet specific process requirements. These include grid-scored, double cut and grooved/perforated forms that have been specially developed for the revo-lutionary DIAB Core Infusion™ process.
... in action
Cost-Effective KitsFor those involved in series production, DIAB cores can be supplied in ready-made construction kits where each piece is pre-cut, shaped, as necessary, and numbered to fit exactly into its designated place in the mold. This substantially reduces build times, saves labor costs, improves quality and virtually eliminates waste.
DIAB Technologies - Realizing Your VisionDIAB Technologies’ role is to help our customers take full advantage of the benefits offered by the DIAB sandwich concept. With their long term experience and knowledge, they can help with specific challenges or be involved in the complete product development cycle - laminate design, structural engineering, prototyping, process auditing, development and optimization, train-ing, manufacture and testing.
DIAB customers can take advantage of the company’s unrivalled level of product support and the specialist skills offered by DIAB Technologies. Our highly skilled and experienced teams are strategically located around the world so that we can offer you global support on a local basis.
& services
DIAB has partnered with Skandinaviska Glassystem to develop this innovative and award winning modular cladding system.
manufacturing
DIAB has strategically-located manufacturing units in Australia, China, Ecuador, India, Italy, Lithuania, Sweden, the USA and Thailand in order to shorten the supply chain and to be close to the customer.
Quality & EfficiencyProduct quality and production efficiency are the watchwords at every DIAB manufacturing plant. In order to achieve both, the company has invested heavily in ‘state of the art’ production equipment and a skilled and dedicated workforce.
Extensive use is made of CAD/CAM equipment to op-timize efficiency and maximize quality. As many of the manufacturing processes are unique and proprietary to DIAB, a high proportion of the processing equip-ment has been designed and developed by the DIAB manufacturing team.
Each plant is accredited to ISO 9001 and meets local, national and international standards regarding envi-ronmental issues.
Think global - act local
research and development
A commitment to continuous improvement and product innovation
DIAB focuses on expanding the application areas for its products by improving the benefits provided by the sandwich concept. At the same time it operates a policy of continuous improvement for all its products and services.
Material BreakthroughsBoth Divinycell F, which was specifically developed for commercial aircraft interiors, and Divinycell P represent significant breakthroughs in core materials technology.
Total Commitment to R & DIn addition to the recent introduction of Divinycell F and P, DIAB has also added additional densities to its Divinycell H and Divinycell HP grades and introduced several new finishing options. Our commitment to R & D enables us to present the most complete range of products and services in the industry and provide solutions to a wide number of markets and applications.
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All content in this publication is protected under international copyright laws.© DIAB Group AB - March 2009
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