Meeting the needs you'll
have tomorrow
We are your global technolgy partner
Whether local or global - we have systematically tailored our range of
products and services to the needs of our customers, and offer assistance
with our many years of experience in everything from planning to production.
Whether small or large - we offer standardized single systems and individual
solutions, which combine a variety of different technologies with a high
level of automation in order to simplify and automate your processes.
Solving problems is good, but creating additional value is better.
Whether local or global – we have systematically tailored our range of products and services to the needs of our customers, and offer assistance with our many years of experience in everything from planning to production.
Our innovative solutions have received 24 SPE Awards. We have 1,400 employees throughout our locations in Europe, America, and Asia, as well as numerous international representatives.
An endless variety of parts can be made using soft, rigid, or integral foam. Our PU processing technology is used for a variety of applications in many industries, such as the sports and recreation and construction industries. We support you throughout the entire process so that even the smallest details meet your specific production requirements. Highly-specialized solutions are common in the transportation industry.
FRIMO PURe tooling and equipment is used in series production around the world in instrument panel, door panel, seat, and headrest production, as well as for insulation and structural components, cable over molding, and much more. In addition, polyurethane-based composite materials are steadily gaining importance in modern lightweight construction.
3D printing has revolutionized the production of leather models for instrument panels. Powdered plastics are used with the stereolithography process (SLA) and, for certain applications, the selective laser sintering process (SLS). This eliminates the need to produce a blank and the entire milling process.
Auxiliary models can be 3D printed to use later as a basis for a galvano shell with the grain. To save even more time, the grain can also be produced by 3D printing. It can be directly incorporated into 3D printing through visual measurement and conversion into a corresponding data set.
Many of these models have already been used, including for the door panel of a current sports car. In this case, FRIMO used 3D printing to create a one-piece leather model consisting of the bolster insert, piping, and mirror area. The manufacturer's original grain was reproduced on the model's surface using the SLA process. It is even possible to create an omega groove on the leather model.
3D printing has revolutionized the production of leather models for instrument panels. Powdered plastics are used with the stereolithography process (SLA) and, for certain applications, the selective laser sintering process (SLS). This eliminates the need to produce a blank and the entire milling process.
Auxiliary models can be 3D printed to use later as a basis for a galvano shell with the grain. To save even more time, the grain can also be produced by 3D printing. It can be directly incorporated into 3D printing through visual measurement and conversion into a corresponding data set.
Many of these models have already been used, including for the door panel of a current sports car. In this case, FRIMO used 3D printing to create a one-piece leather model consisting of the bolster insert, piping, and mirror area. The manufacturer's original grain was reproduced on the model's surface using the SLA process. It is even possible to create an omega groove on the leather model.
All products are customized and can be laid out according to the customer's requirements. We would love to show you your options.
FRIMO supplies foam tools, casting tools, and spray tools for a variety of polyurethane part applications. Our product portfolio ranges from simple tools for prototypes to pre-production tools and the most complex production tools, such as for back foaming premium decor materials or front foaming with the optional FRIMO PURe Liner.
By taking the part geometry, volume, and individual customer requirements into account, we offer the most technologically and economically suitable solution for your PU application. We would love to show you your options with FRIMO PU technology.
Our standard tool carriers meet all kinematic, clamping force, and clamping area requirements and can be used in stationary systems, turn tables, and overhead track systems. We've built well over 1,000 tool carriers, proving their reliability in production of both small and large parts.
FRIMO is your specialist for meeting customer requirements for optimal tool carrier concepts and specialty models. Our product portfolio includes a broad range of possible special designs, including for parts such as window frames, damping elements, cast skins, skis, acoustic parts, boilers, glass roofs, steering wheels, seat cushions, and headrests.Our standard tool carriers meet all kinematic, clamping force, and clamping area requirements and can be used in stationary systems, turn tables, and overhead track systems. We've built well over 1,000 tool carriers, proving their reliability in production of both small and large parts.
FRIMO is your specialist for meeting customer requirements for optimal tool carrier concepts and specialty models. Our product portfolio includes a broad range of possible special designs, including for parts such as window frames, damping elements, cast skins, skis, acoustic parts, boilers, glass roofs, steering wheels, seat cushions, and headrests.
Large parts pose special challenges. Our tool carriers allow optimal tool handling, even for large and heavy tools. Highspeed closing and opening, as well as individually adjustable swiveling motions that bring the tool to the optimal position for the operator and for handling, ensure a smooth process.
The machine variations in our product portfolio differ in controls and kinematics. In addition to our standard machines, we offer the opportunity to customize the layout and options based on your specific project requirements. Special configurations can easily be integrated into highly-efficient and flexible production environments. Examples of these include shuttle systems or tool carriers that run either separately or continuously on an overhead track system (PURe TRACK) or on a floor track system (PURe FLOOR).
Our sophisticated tool carriers enable small PU parts to be produced efficiently in both low and high volumes with foam molding, front foaming, or back foaming. Designs with specific opening and closing motions to suit every project and production environment are available.
The extremely compact design of the tool carriers makes it easy to integrate them into your production process, even in the smallest spaces. The dimensions can be customized, and vary based on the part and tool dimensions. Multiple cavities can be used on a single platform for economic production. If you want to use existing foam tools, we can quickly create a solution for your requirements with our modular concept.
We use our years of process experience to give you machines that produce your PU parts cost-effectively and efficiently. We off a wide variety of solutions for combining tool carriers and metering machines, including everything you need for a complete production system.
Our portfolio includes PU stationary machines and turn tables for continuous or cycled operation.
In addition to these well-known machines, systems with an overhead or floor track are also an interesting option, as they combine maximum flexibility with high productivity. The style and layout of all FRIMO PU equipment can be adjusted to suit the customer's wants and the space available.
Customer-specific machine layouts with
Our stationary systems are configured based on the project and laid out to make the best possible use of the available floor space. The tool carriers in these systems are positioned for optimal operation, handling, and logistics.
FRIMO PU stationary system advantages
Turn tables are best for consistent production volumes that can be planned for ahead of time with few variations. Multiple tool fixtures are mounted to a rotating table where they are moved from one workstation to the next. Additional processes can be integrated, such as surface activation on the part. Robotic handling allows material inflow and outflow to be fully-automated. In certain cases, it is possible to connect turn tables and stationary machines, combining the advantages of both concepts.
FRIMO PURe RT Turn Table Advantages
With the PURe FLOOR track system, tool carriers travel with the tools to different processing stations along a monorail. This concept provides maximum flexibility in all areas. Not only can the track layout be customized, but also the speeds at which individual carriers, or groups of carriers, travel between different areas of the system. This system can be expanded in multiple stages, though its advantages can be experienced in the first stage.
FRIMO PURe FLOOR Floor Track Advantages
The modular FRIMO overhead track system, PURe TRACK, provides maximum production flexibility. This system offers multiple expansion options and can produce small, medium, and large parts. Tool carriers with high clamping forces and tool weights are possible. They are guided by a double track system that hangs from a gantry mounted to the floor.
FRIMO PURe Track Overhead Track System Advantages
FRIMO is a full-service supplier for PU processing. FRIMO and Hennecke have a cooperation called the Automotive Alliance for wet technologies. FRIMO therefore offers the complete range of metering technology from Hennecke. This applies to both single-station machines and machines integrated into complete production systems, which can be used in every area of polyurethane processing, from soft, semirigid, rigid, and integral foam processing, to foam-in-place and spray systems.
All models are based on sophisticated, refined concepts with reliable standard components. The machines have been optimized for maintenance and operation. Modern controls and display systems create a reliable process and ensure consistent high quality. All high pressure and low pressure machine models include extensive standard equipment, which can be supplemented with a variety of options geared towards your application. We would love to help you find the perfect metering solution for your product.
TOPLINE metering machines are best-in-class for high-pressure polyurethane processing and are the centerpiece of numerous polyurethane processing systems.
Our HIGHLINE high-pressure metering machines are great for small spaces and high energy efficiency. You don't have to make any compromises on performance or reliability with this model.
With MICROLINE systems, you aren't foregoing the reliable components used in the TOPLINE series. By combining different mix heads, you can complete versatile applications according to your requirements.
The STREAMLINE MK2 concept is an optimized high-pressure metering machine with innovative details that are customized to meet the requirements of CLEARMELT and CLEARRIM applications. They produce transparent, durable polyurethane coatings for decorative parts.
COLOURLINE high-pressure metering machines are used for finishing surfaces on decorative elements in the automotive industry, furniture industry, and for numerous other applications that require multiple colors. The COLOURLINE is an isocyanate unit permanently installed on the injection molding machine.
The IMPACT series takes the special requirements of low-pressure processing into account. This robust system can reliably handle most standard applications.
HK-R 5000 low-pressure metering machines are perfectly laid out for intermittent production of open-cell polyurethane foam blocks. It is mostly used for applications that required high outputs, such as producing foam for headliners in the automotive industry.
For processing casting systems and polyurethane-based raw materials, the name ELASTOLINE has been known for decades to mean high-quality, premium finished products. Through the Automotive Alliance, FRIMO is now able to offer ELASTOLINE series low-pressure machines from our strategic business partner, Hennecke.
The next evolutionary step in elastomer processing is production without material and solvent loss through ELASTOLINE high-pressure technology. Along with cost savings, the high-pressure concept makes sustainable production possible by conserving resources.
The ELASTOLINE offers a flexible machine concept for processing MDI and TDI-based raw material systems, perfectly adapted to meet your requirements. For processing NDI systems (such as Vulkollan®), the ELASTOLINE V has a high-grade tempering concept for optimally conditioning the components.
Avoid the disadvantages of low-pressure processes for elastomers with the ELASTOLINE HP. Material and solvent losses do not occur with high-pressure technology, which conserves resources and increases savings.
FRIMO PURe Mix Heads are available in both two-component and multi-component versions. Various sizes are available for the smallest to the largest applications. Straight mix heads are particularly ideal for injecting into a closed tool, while L-heads create advantages in laminar foaming.
We have mix heads available for selective or permanent mixing of up to six components. For RTM processes, we offer an advanced mix head with servo-pistons for three components.
With this mix head, the reaction profile and injection strategy can be adjusted according to the part requirements to reduce processing time.
The advanced FRIMO air-assisted spray head offers the widest range of process parameter variables and increased repeatability with the lowest possible material use.
MT mix heads have been completely re-engineered and guarantee optimal processing of the entire range of popular PU systems. Up to six components precisely enter the mixing chamber through injection nozzles.
Slot-controlled straight mix heads in the MN series are particularly for polyurethane spray processes (PU CSM technology) and applications with components that contain fillers. The easy-mount design also makes these mix heads predestined for RIM processes.
Cast systems, high viscosity materials, or reactive components and additives make mixing through reverse flow impossible. This is where the MEL series of mix heads comes into play, with special agitators inside the mixing chamber that ensure uniform mixture and steady flow, even for especially challenging systems.
Multiple unique trimming projects create a need for flexible solutions. Our FRIMO FlexTrim machines are capable of any cutting process, allowing them to precisely and reliably meet even the most complex requirements with the smallest tolerances.
Precise cuts play an important role in the final quality of premium plastic components. Different geometries, materials, material combinations, and project requirements, such as volumes and the production environment, result in many unique project definitions. Our robot-assisted FlexTrim technologies guarantee the best solution to suit your needs.
Both simple and complex cuts can be precisely achieved, over and over again. We provide support right from the start, throughout engineering, prototyping, and the production of your tooling and equipment. In addition to our standard products, we offer custom and turnkey solutions that combine and automate various technologies and processes.s
During ultrasonic cutting, a frequency generator causes a very specialized blade to vibrate. The blade makes thousands of cutting strokes per second, controlled by the frequency set on the generator (usually 20-40 kHz). The blade and frequency are matched to your project requirements to help you achieve the best possible cuts.
This process is characterized by how clean, quick, and versatile it is. Maintenance is almost completely eliminated. Combining the advantages of ultrasonic technology with our robust, reliable machine technology is an interesting option for many applications. Interior and exterior automotive parts, packaging materials, and composite materials can all be processed efficiently.
Clean, fast, and flexible
With FRIMO FlexTrim Milling Machines, we offer custom solutions for a variety of cutting applications. Our milling technology is especially well-suited for processing complex part geometries with defined cutting/milling depths. Many customers also use our machines to supplement the punching process or to produce low-volume part variations. We offer not only proven machine technology, but also sophisticated production concepts, even for high-volume projects.
Sophisticated fixture concepts are the heart of our machines. The better the fixture fits your project, the more efficient your serial production will be. Debris is a process-related issue for which we offer solutions unique to the market. We even have flexible solutions for waste removal and transport.
Standardized and modular
Perfectly prepared with FRIMO surface treatment
Robot-assisted systems are our specialty. Surfaces are, too. That's why we offer robot-based solutions not only for flexible trimming, but also for surface treatment. FRIMO flame and plasma treatment machines specifically prepare plastic substrates for the subsequent process. The robot-assisted surface treatment occurs through either flaming or plasma technology.
The treatments increase the surface tension of the parts to ensure optimal adhesion of foams, coatings, or lamination applied afterwards, resulting in impeccable quality and permanent bonds. Areas of the substrate that should not bond can be shielded from the gas flame treatment.
Scoring technology is used in the automotive industry for skin weakening in airbag areas on instrument panels and door panels. Highly-specialized blades and our online tracking are used to score targeted break-through areas that ensure controlled airbag deployment. Maximum precision and flawless quality are absolute musts. The material and application determine which of our variety of different blade systems to use.
Our scoring systems are the market's technological leaders and are available in a variety of designs. We have exclusive process technology for incorporating release agents to achieve optimal results. Sophisticated error-prevention concepts, such as online tracking, positioning aids, skin thickness measurement, blade disposal stations, and poka yoke ensure the highest possible output of flawless parts.
When it comes to high volumes, you can trust our efficient punching equipment to get the job done. We are experts in all punching processes, even for highly-complex and large parts. We also offer automated and linked systems.
At FRIMO, you get comprehensive and optimally-customized punching solutions for a wide variety of applications. We are the leading specialist in high-volume, complex punching projects. Our systems are used across the globe in the automotive industry for punching instrument panels, center consoles, door and column panels, and bumpers. The punching methods we use encompass all principles of die cutting and kiss cutting.
Additional special types of punching can be combined with each other or with other processes, such as edge folding. For these special situations, we have automated and connected systems. Your advantage? 100% reproducible, highly-precise punch results with short cycle times, an efficient process, and minimal floor space requirements.
FRIMO's EcoCut punching machine is ideally suited for trimming very complex and large plastic components such as instrument panels, door panels and armrests. Its high capacity makes it the optimal choice for high-volume production.
The EcoCut is specifically developed for trimming in RAM and many additional punching directions. The product fixture is integrated directly into the lower table. The vertically driven upper tool replaces the press ram.
FRIMO EcoCut Advantages
FRIMO's EcoCut punching machine is ideally suited for trimming very complex and large plastic components such as instrument panels, door panels and armrests. Its high capacity makes it the optimal choice for high-volume production.
The EcoCut is specifically developed for trimming in RAM and many additional punching directions. The product fixture is integrated directly into the lower table. The vertically driven upper tool replaces the press ram.
FRIMO EcoCut Compact Advantages
FRIMO's EcoCut U was developed to bring you proven technology and total flexibility. This compact, ergonomically-designed punching machine is ideally suited for trimming very complex and large plastic components such as instrument panels, door panels and armrests in high volumes.
The flexible layout can be adjusted according to your needs and can be added onto later as needed. This allows you to start out with a simple machine that can be built up for fully-automated tool changes and robotic part loading and unloading.
FRIMO EcoCut U Advantages
Fiber composites are essential to modern lightweight construction because they can be customized in many ways. Using our extensive experience in composites, we are able to offer the best possible thermoplastic and duroplastic process tooling and equipment technology for lightweight and structural parts.
Developing innovative tooling and equipment for lightweight construction is one of our distinctive capabilities. We offer support from the very beginning for development of new, cost-effective processes, alternatives for established processes, and substitution of steel and aluminum parts. As a global partner for simple to complex tasks in fiber-reinforced materials, composites, and lightweight construction, we take all the details of your lightweight construction requirements into account during the design development phase.
Our FRIMO composite experts support you in the early development phase as far as feasibility, possible weight reduction, and resource-efficient production and automation, and offer custom production solutions for preforming, forming, pressing, and injection molding. Together, we can help you go from an idea to profitable composites production.
Natural fibers are so attractive for industrial use because of their good mechanical properties, such as rigidity and stability, and combine good insulation properties with lower densities. If there were a formula for success for sustainable lightweight construction, it would be based on combining natural fibers with polypropylene. The composite material NFPP is popular in the automotive industry, particularly for the production of interior paneling, not only because it is lightweight, but also because it is well-suited for many process combinations.
Through our NFPP Hybrid technology, we combine forming, trimming, and back injection, which allows functional elements to be integrated. With our NFPP OneShot technology, we combine multiple processes, such as forming, laminating, and trimming.
NFPP technology is ideally suited for producing semistructural substrates. This is typically seen in door panels for automotive interiors. To produce these substrates, natural fiber mats with a thermoplastic PP matrix are heated, precompressed, and then formed and trimmed in a compression tool.
With the NFPP OneShot process, decor materials, such as carpets or interior surface materials, can be compressed and trimmed with the substrate in one step.
FRIMO NFPP Hybrid technology combines forming, trimming, and back injection of ribs and fasteners. This maximizes the potential to integrate additional functional elements directly into the part, such as reinforcement or weld domes, and eliminate follow-up processes, such as welding. NFPP Hybrid technology can be combined with OneShot technology. If you are using many tools for low-volume production, our single-station machines are a great option. If you want your investment for high-volume production to be as profitable and sustainable as possible, we recommend a double machine with two tools.
We do everything we can to bring all of your design and functional requirements to life. Our tools embody our extensive experience, gained from countless projects with both low and high production volumes. That's exactly why our work begins well before design. During the conceptual phase, our Pre-Engineering Team determines how to optimize production of your part and uses this information to develop a suitable tool concept. From the very beginning, we start thinking about a number of factors: detailed part examination, clamp frame technology adjusted to the contour and material, possible slider collisions, formability rating, possible degree of automation, and issues such as targeted over-compression and waste removal. The tool layout is optimized with the help of filling simulations generated from your actual process parameters. We also look into possible material process combinations in our FRIMO TechCenter.
Organo sheets are high-performance, semi-finished materials with carbon, glass, or aramid fiber fabrics embedded in a thermoplastic matrix. Our fully-developed Organo Sheet Injection process (OSI) features short cycle times for thermoplastic structural components that are not only considerably lighter, but that can also include many functions.
Additional functional elements can be integrated with back injection, including mounting eyes, weld domes/ribs, or targeted reinforcements, and the edges of the part can be perfected. The costs of handling and storage are significantly reduced through combining the processes in one step.
During the FRIMO OSI process, the organo sheet is formed in the tool and back injected within a single step. This translates into noticeably shorter cycle times, tool savings, and therefore increased profitability.
Process combinations and functional element integration make back injected organo sheets attractive and efficient for innovative lightweight construction applications in many different industries. One example of this is clips used for the fuselage of the Airbus A350 XWB. Carbon fiber organo sheets replaced the typical aluminum design. The multitude of different geometries, of course, resulted in a multitude of tools. Because the fully-automated tool changes are integrated into the customer's data logs, thousands of different clips can be produced flawlessly and reproducibly in the shortest cycle time.
Along with the established organo sheet back injection process, there are additional processes for making thermoplastic hybrid structures. Organo sheets or custom direct long-fiber thermoplastic UD tapes (D-LFT) can also be strengthened or functionalized with back pressing. Through the additional combination with D-LFT tapes, the advantages of both materials are brought out because their special flow behavior allows more design freedom. Rib structures or reinforcements can be formed and additional functions can be integrated through metal inserts.
With this new process, the lightweight potential of LFT applications for thermoplastic fiber reinforced structures can be fully recognized. An innovative tool design is the center of this process. The entire production process occurs in cycle times of less than one minute. Using a pressing process eliminates the need for hot runner technology in an injection molding process.
RTM (Resin Transfer Molding) processes offer the best conditions for producing extremely efficient and resilient structural components with maximum potential for weight savings. Fiber fabric preforms are placed in the tool and the closed tool is injected with a reactive resin system under high pressure. The various matrix materials, such as epoxy or polyurethane-based materials, each create specific process requirements.
We provide feedback to help to optimize production of your part and supply not only tailor-made tooling and equipment, but also complete production solutions. Our focus is on continuing to develop the RTM process and the production process for fiber composites in high volumes. The fastest injection process possible and short amount of time the part spends in the tool contribute to shorter cycle times. The composition of the preform also has a significant influence on the mechanical properties of the part.
The preforms play a key role in the RTM process. The better the preform, the better the structural part. Preforming therefore plays a large role in the configuration and cost-effectiveness of the process. Preforms are produced in advance by putting the textile materials through a dry preforming process. Producing the preforms in advance eliminates the influence of viscous resin displacement, which considerably raises the reproducibility compared to wet compression. In addition, fiber direction can be optimized for the process and different textile materials can be combined. With targeted material feeding and sophisticated draping methods, even complex geometries are feasible.
We offer systems for compression preforming (contact heating, IR heating, compression molding), handling (transferring and robotics), and preforming tools. We can also implement alternative preforming processes and integrate them into a complete concept.
Minimized cycle times, maximum performance
FRIMO Wet Compression Molding (WCM) machines are fully automated and capable of producing both monolithic or sandwich-style fiber-reinforced structural automotive components. The WCM process allows the use of fast cure resin systems and therefore offers significant cost and cycle time advantages over RTM processes.
Compared to RTM, the pressures used for forming are much lower, allowing for integration of lightweight sandwich cores (e.g. pre-milled paper honeycomb), complex 3D PU foam cores, or pre-assembled PET foam pieces. FRIMO offers not only tailored tool and pressing technology, but also custom solutions for automated manufacturing of sandwich cores.
During the first step of the wet compression molding process, a reactive polyurethane or epoxy resin is applied to dry, pre-cut glass, carbon, or aramid fiber material. The impregnated fiber stacks are then automatically inserted into the press. Using pressure and heat, the parts are molded and the matrix materials cure simultaneously.
Our thermoforming technologies offer a variety of innovative options to help increase efficiency. Both rolled foils and sheet materials can be used to produce decorative trim parts.
Our thermoforming technologies offer a variety of options to help increase efficiency. Both rolled foils and sheet materials can be used to produce decorative trim parts.
During deep drawing, thermoplastic materials are warmed and contour formed. Vacuum laminating, on the other hand, involves heating a TPO or PVC foil and vacuuming it to the substrate, where it is then glued. IMG (in-mold graining) is possible with both processes, meaning the desired grain of the decor is incorporated into the tool shell and imprinted on the surface during the forming process. Most FRIMO machines are capable of having one or more of these processes integrated.
Starting in the development phase, we use 3D simulations and visualization technologies to optimize your series process parameters and shorten start-up times. A variety of patented FRIMO concepts help with energy and material savings. Our extensive standard thermoforming machines can also be equipped with many additional features.
It is important to us that your equipment offers the highest possible operational availability and is ergonomically optimized for your operators, regardless of whether they're producing small or large quantities. You can only satisfy your customers' requirements in the long run with well-engineered processes that are specifically developed to suit your needs.
FRIMO EcoForm machines are designed as standardized single-station machines for deep drawing and vacuum laminating foils and sheet materials. FRIMO VarioForm thermoforming machines are primarily used in the automotive industry and are ideally suited for forming a wide range of films and sheet materials. Both thermoforming solutions can also be used in the IMG process (In-Mold Graining) to achieve surfaces with a perfect grain.
Innovation topics, such as autonomous vehicles, will have a lasting influence on future automotive interior designs. At the same time, the number of vehicles with individualized model and interior variations continues to rise, and with it the demand for flexible, all-purpose production processes. Our deep drawing and vacuum laminating machines position you perfectly to fulfill these requirements.
FRIMO VarioForm in-line machines are a perfect fit for economically deep drawing or vacuum laminating. A variety of concepts and models are available to fit every application. No matter which model you choose, cycle times for producing premium decorative trim parts for automotive interiors can be greatly reduced. Decorative surfaces for automotive interiors are a typical example. We have been continuously developing our machine concepts for decades at FRIMO.
Technically detailed solutions for reliable, cost-effective, competitive production are what make our machines stand out. Patented FRIMO concepts save materials and energy. In addition to the advanced standard model, there are numerous additional options to make your thermoforming equipment completely unique.
A high-quality look and feel, along with innovative technology, play a big role in in today's automotive interior design. It can be challenging to use traditional thermoforming processes when trying to minimize grain stretch, maintain grain harmony between parts, and incorporate airbag logos, decorative stitching and different grain areas on a single part. During in-mold graining (IMG), the grain is first created on the foil during the deep drawing or vacuum laminating process.
The ungrained and warmed foil is suctioned directly during the forming/laminating process into a contoured, grained shell. The grained surface of the shell is then imprinted on the warmed foil (TPO foam/compact sheet). The IMG process combines the economic aspects of classic thermoforming technologies with the quality advantages of modern skin forming processes. It makes it possible to produce surfaces without visible grain stretch and manufacture parts with impressive grain quality.
We offer support as early as the product development stage to help you achieve optimal thermoforming results in series production. With our 3D thermoforming simulation, you receive reliable predictions on feasibility, the optimal tool layout, foil usage, and attainable quality. Simulations are done primarily on thermoplastic compact or foam foils, mainly focusing on foil thickness, stretching, or wrinkling. Sheet materials up to 5 mm thick can also be simulated.
Different thermoforming processes can be compared to find the best solution for your application. Almost all thermoforming processes, as well as in-mold graining (IMG), are possible and process parameter changes can be quickly integrated into a new simulation. This helps significantly reduce the length of the development and start-up phases.
The goal of the heating process during thermoforming is to heat the foils as quickly as possible, both in defined areas and across the entire surface. FRIMO has developed a new foil heating process specifically for this reason, called Time Shifted Heat Control (TSHC). The key is a specially-developed calculation algorithm, which switches the emitters on at the right time, taking overlap and peripherals into account.
The challenge is determining the optimal operating method of the IR emitters, which influence each other and have overlapping radiation fields. Thus FRIMO TSHC uses the optimal efficiency of the emitters to warm the foil.
Unique design details make surfaces stand out. The designs of our press lamination solutions are just as unique as the materials and requirements in your project, and they provide maximum material savings and efficiency. This is achieved through the FRIMO Accurate Blank Laminating (FABL®) process, by processing optimized contour-cut blanks, including the edge fold, within one machine.
Unique design and quality combined with material savings and productivity - for superior precision you can see and feel. Today’s requirements for producing decorative surfaces for automotive interiors are challenging, and the development of unique, cost-effective production solutions is one of FRIMO's distinctive capabilities. We are an established, leading specialist on the market for press laminating systems. Our variety of efficient press lamination tooling and equipment helps add the finishing touches to your substrates with premium surfaces such as leather, artificial leather, textiles or foils, combined with either PU foam or spacer fabrics.
Interior components can also be upgraded with unique colors or with decorative and functional stitching. IMG formed skins
with stitching are another premium option. The bond between the substrate and the decor results from a gluing/joining process with specific pressures and temperatures. There are almost no limitations to the design of the parts; all geometries can be processed with our tooling. The result is high-quality parts that can be produced in a repeatable, reliable, and efficient way in series production volumes.
Leather laminating is found mainly in the automotive industry. High quality vehicle interiors are characterized by a sophisticated design made of perfectly processed and adapted materials. Leather surfaces are no longer exclusively reserved for premium vehicles; they are also becoming increasingly used in high volume and mid-priced vehicle interiors.
As a natural material, leather presents tough processing challenges. Processing delicate materials, like leather, efficiently and with repeatable quality requires special know-how. The individual processes – surface treatment, adhesive application, and the actual leather lamination – must be precisely coordinated.
Variations, quality/quantity requirements and numerous project-specific parameters demand smart manufacturing solutions that can only be produced with extensive experience and in-depth technology and process expertise.
FRIMO's tooling and equipment technology in leather processing leads the market. Along with leather laminating come leather back-foaming (PU processing) and leather scoring for hidden airbags.
The success of our robot cells stems from creating clever combinations for fast production. These combinations are a more efficient alternative to having multiple machines for medium to high volume armrest, door upper, bolster insert, and instrument panel production. "All in One" means combining pre-fixing, hotmelt adhesive application, and the subsequent press laminating/edge folding process in a single production unit.
By combining these individual steps, and handling parts for adhesive application with robotic support, resources are reduced in multiple areas. Less space and fewer operators are required. The result: attractive soft-touch surfaces made of leather, artificial leather, textiles, or films with polyurethane foam or spacer materials. Plus, all production parameters are permanently recorded, making the process incredibly reliable.By combining these individual steps, and handling parts for adhesive application with robotic support, resources are reduced in multiple areas. Less space and fewer operators are required. The result: attractive soft-touch surfaces made of leather, artificial leather, textiles, or films with polyurethane foam or spacer materials. Plus, all production parameters are permanently recorded, making the process incredibly reliable.
It is simply not possible to save more material during press laminating than with FABL®. This advanced press laminating technology can process exact contour-cut blanks made of TPO/PVC sheets, textiles, or artificial leather.
These are then positioned, laminated to the substrate, and edge folded all in one step. FABL® reduces material waste and increases production efficiency for premium surfaces in a flexible, sustainable process.
With FRIMO Accurate Blank Laminating, or shortly FABL®, the decorative material is pulled tight by electric positioning grippers, which eliminate any possibility of wrinkles. Other advantages include minimized grain stretch and higher remaining wall thickness, which ensure a high-quality, premium appearance. This is achieved through exact positioning and controlled decorative material slippage. The parts are laminated and edge folded all in one step. FABL® reduces material waste and increases production efficiency for premium surfaces in a flexible, sustainable process.
FRIMO Groove laminating allows you to use different decor variations on a single substrate. It is most commonly utilized on doors in automotive interiors.
There is only one condition: the substrate must have a groove to tuck the edges of the decor into. During the process, a blade tucks the edges of the decor into the substrate's groove, where it is secured with adhesive.
During the groove laminating process, a blade tucks the edges of the decor into the substrate's groove, where it is secured with adhesive. Both 2D and 3D contours are feasible and edge folding can also be integrated when necessary. This makes it possible in a fast and efficient way to highlight a certain area of a door panel using a textile, leather, or foil, without needing to produce a separate substrate.
Press lamination solutions are quickly gaining importance in the automotive industry compared to classic vacuum lamination. With autonomous vehicles, interiors in particular will undergo a complete redesign. New materials and functions also bring new challenges for volumes and technical requirements. Customization will become even more popular.
Our customers need tooling, equipment, and processes that can variably and cost-effectively process as many different surfaces as possible. The need for product-specific solutions is growing to make part production optimal for functionality, quality, reliability, and efficiency.
We think ahead of the curve to finish your products using a reliable process without rework, and with perfect edges. We don't have a one-size-fits-all solution; instead, we have a variety of unique solutions, which can be seamlessly combined with other technologies. This helps us efficiently achieve your highly-complex tasks.
We think ahead of the curve to finish your products using a reliable process without rework, and with perfect edges. During edge folding, excess decor is wrapped around the edges of the part and glued to the back. This improves the appearance and assures the quality of the part.
If an adhesive is used, it is activated with utmost precision by a segmented 3D hot air or infrared heater. Material tolerances can be regulated through the use of our specially-developed FRIMO edge fold sliders.
Adhesive-free applications use heated sliders or hot air.
We offer a variety of custom solutions, which often can be combined with other technologies, such as punching, joining, or various quality assurance processes. This helps us achieve your highly complex tasks. Process reliability is ensured at all times through continuous process parameter control, resulting in a very low-maintenance process.
Integration of other technologies into the edge folding process
FRIMO edge folding systems with adhesive activation allow adhesives to be activated through heat, and come in the following technical configurations:
FRIMO edge folding systems without adhesive activation use either contact adhesives or hot-melt adhesives that are applied shortly before edge folding and are already activated. Temperature-controlled sliders are used to apply the adhesive.
FRIMO edge fold systems that do not use adhesives are very efficient and allow short cycle times of under 35 seconds. Empty nest part loading and integration of punching, welding, clip assembly, or inspection are possible options.
Our customers associate us with high quality, making us a strong partner when it comes to perfect material bonds. We will help you find the right welding or riveting method or combination of methods for your material combinations, part geometries, and volume requirements.
Joining applications are becoming more complex and diverse, and quality requirements are increasing. Different processes are used depending on the application area and the material combination, part geometry, and volume requirements.
Considering weldability during the design stage creates advantages later on. This is because the only way to compensate for tolerances and guarantee reliable welds is with perfectly designed weld-seam geometries. Our special FRIMO controls technology also plays a considerable role in the efficiency of the processes.
Thermoplastics can be welded together using INFRARED radiation. Some of the radiation in infrared welding is absorbed by the material and transformed into heat. As a result, the surface layer is melted and the plastic components can be joined by being pressed together. Infrared heat is transferred without contact. The heat input is fast, specific and energy-efficient.
Power-controlled and time-controlled INFRARED emitters allow for precise and controlled welding processes. Typical applications are instrument panels, door trims and center consoles with complex, 2D or 3D welding contours. Particle-free welding is particularly used for joining air-duct pipes, fluid containers, tank systems and filters or filter housings.
The FRIMO hot plate welding machine portfolio includes standard machines in various sizes for welding parts with different measurements. One of the most common applications is glove boxes. All machines come with the option of adding a standard tool change system.
These standard machines are multi-functional for continued use. Cycle times can be shortened through perfected programming. FRIMO also offers a variety of automated solutions.
Ultrasonic welding is a quick, energy-efficient process, suitable for large quantities. Typical automotive industry applications include door panels, add-on parts for instrument consoles and other vehicle interior trim pieces.
FRIMO offers everything from simple equipment to complex, robotic welding systems capable of processing different parts in a single system.