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Wabtec Bespoke Composite Moulding Manufacture Support

Bespoke Composite Moulding Manufacture

Brecknell Willis Composites manufactures high quality composite mouldings ranging from hand held Arc Shields to Train Cabs & 23 Meter Radomes.
 
Resin Systems:

  • Polyester: A general purpose system that can meet Fire specifications from CLASS 3 to 1.
  • Synolite 5001-T-1: For Electrical protection used for many Arc Barriers and Arc shields.
  • Phenolic: Exceptional fire, smoke and toxicity performance.
  • Vinylester: Extremely stable, perfect for tooling and moulds.

 
Reinforcements:

  • Chopped strand Glass Fibre mat
  • Woven Glass & Carbon Fibre Fabrics
  • Foam Core reinforcement

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Calendering

Premium rubber coated fabrics and sheet stock available cured or uncured. Custom compounding, configurations in a range of elastomers and fabrics (some U/L listed). Excellent for use in molded applications as well as gasket and die cutting material

Wabtec Composite Finishing Paint Assembly Servicing

Composite Finishing and Assembly Service

Brecknell Willis Composites boasts an expansive finishing workshop. 
 
Finishing

  • In-house spray paint & bake facilities
  • "Self-coloured", Gelcoat finish mouldings

Assembly
For more complex components, some assembly is required. This may involve drilling holes, adding threaded inserts or bonding other reinforcement onto the composite material.
 

Wabtec Repairs Composite Refurbishment Service

Composite Refurbishment Service

Due to the adaptable nature of composite materials, many components can be repaired after being damaged or worn out. Brecknell Willis Composites offers regular refurbishment and modification services to extend the lifespan of their customer's GRP products.
 
Refurbishment services:

  • Product modification
  • Insert replacement
  • Cosmetic repairs
  • Structural Composite repairs

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Elastomer Bonding & Overmolding

Rubber-to-fabric, rubber-to-metal and rubber-to-phenolic / thermoset. Specially formulated adhesive systems strong enough to provide consistent bonds that withstand flexing and chemical attack found in harsh environments

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Mandrel Building

Supported and unsupported elements from 1" to 30' long in a range of diameters. Autoclave curing (30" high x 52' long or 78" high x 53.5' long). All rubber, fabric-reinforced rubber and metal-reinforced rubber

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Molding

Compression, injection and transfer molding. Rubber, bonded rubber / overmolding, phenolic and thermoset materials with custom formulations available. Small to large part sizes; low to high volume production capabilities.

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Orcomatic Molding

Proprietary molding process. Cost effective solution for continuous, high-volume production of small components with single or multi-cavity setups.

Wabtec Patternmaking  service layup infusion bagging tooling

Patternmaking Facilities and Expertise

Brecknell Willis Composites offers a comprehensive in-house patternmaking service. This allows BWC to collaborate with customers to produce bespoke tooling before manufacture commences, ensuring the pruduct supplied meets their exact requirements.
 
Manufacturing processes:

  • Hand layup
  • Vacuum infusion
  • Vacuum bagging
  • Cold press tooling

Quality & Services

Quality & Services
We provide extensive services, which fully comply with customer requirements. 100 years of experience and our technical expertise in development, production, maintenanceafter sales service/spare parts and quality practice go into these services. We take care of our customers’ and clients’ needs, apply a holistic and solution-oriented thought process, act flexibly and help quickly at home and abroad.
As a manufacturer, we supply you with original spare parts “Made in Germany” during the entire application period of our products.
 
Development
Constructive know-how for customised solutions
The main focus of our constructive services is in compiling solutions made to measure for challenging assignments together with our customers. From the idea of a producible component as a one of a kind or serial product. Numerous innovations and records attest to the quality of our constructive work.
Many of our teams of engineers have international experience and have been working together in well-established project teams for many years. Professional equipment and tools go without saying. Efficient processes throughout all phases also ensure the economic success of the project for our clients.
Creative design

  • Engineering work for international sales orders
  • Development of serial products and special-purpose solutions 
  • Upgrading and optimisation of existing customer systems
  • Modification of our own standard series and technologies
  • Development of innovative technologies/system solutions
  • Constructive work in international joint projects

 
Service and Maintenance
Ensuring ongoing availability
Routine and all-round maintenance prevents uncontrollable downtimes. Upon request, we put our own as well as third party components and products through their paces.
We strive to make mobile equipment available at all times in everyday industrial life. For this purpose, we have competent and skilled service technicians at our disposal with standardised tools and equipment. We would be more than happy to compile an individual maintenance proposal for you.
 
Acting instead of reacting

  • Routine, predictable maintenance intervals
  • Application of original spare parts
  • Ensuring ongoing availability
  • Direct cost control

 
After sales service/Spare parts
High class German workmanship for international markets
We cover the entire production range of our energy and data transfer systems in a 15,000 sqm roofed production area. We manufacture, assemble and carry out a thorough inspection of technical core components as well as most of the products before delivery. This makes it possible for us to quickly manufacture high quality spare parts for your requirements and to provide our customers with them just as quickly.
Extraordinary expertise in development and production enables us to advise each customer individually and to support each customer effectively in any situation. Lean structures, dedicated employees and state-of-the-art machinery ensure punctual delivery.
 
High quality work from A to Z

  • short reaction times according to customer requests
  • efficient product development based on proven and tested technologies/model ranges
  • production according to international standards and directives
  • internal assembly, quality control and testing
  • quick delivery, even for large contract volumes
  • extensive customised services

 
Quality Management
Highest quality for satisfied customers
The quality of our services and products is aimed at the complete fulfilment of our customers’ wishes, needs and expectations. In the process, the benchmark for the assessment of our quality is first and foremost set by you - our customer.
Internal quality management ensures compliance with international standards and directives. The implementation of the QM system is carried out according to standardised methods and with the help of flexible tools for the modelling and documentation of all production and business processes (DIN EN ISO 9001:2008).
 
Certificates and Approvals