Film for Composites

Release High Tech Films used for the Manufacturing of Composites

In general, there is a tendency to underestimate how much a modern film can really do in the production of composites, particularly in the manufacture of composite tubes.

Most people simply define it as a “release film” referring to the most obvious, but certainly not the most important, function that the film plays in the production of composite tubes.

In terms of production costs of raw materials, if it is compared with the costs of prepreg; carbon, kevlar or glass fiber; epoxy, polyester or phenolic resins, the cost of the film is always a small part.

If the parameter is instead the total value of the finished composite product, the cost of the film is even much smaller, it becomes completely marginal.

The perspective changes dramatically if using the wrong film, or misusing the right film, results in a defective product. In both cases the composite may be defective and / or its performance limited, lower than what could be obtained.

To give an example, a customer recently improved the quality of his tubolar composite simply by reducing the winding pitch of the film. With a large pitch the surface of the composite had small surface holes (“pores”) created by the resin during polymerization. The tubolar item is aesthetic and this superficial defect is unacceptable. With a tighter pitch, and using the same film, all these problems have been solved.

Furthermore, generally the film is a consumable material, a component that is thrown away at the end of the production process and, also for this reason, is considered of little importance. If design, production and quality control have a superficial approach, and do not dialogue with each other, these strategic characteristics of the films always remain hidden, in the background. If instead production and quality control go in depth, experiment with different production configurations (changing only one parameter at a time) and then refer the results to the design, the best result can quickly be reached, with optimal characteristics of the composite item, and establish a virtuous circle, which allows further improvements to the composite piece.

Our experience and the experience of our customers is very different. A proper use of film (or a combination of films) can drammatically improve the result and determine the success or failure of a composite product.

The Functions High Tech Release Films can accomplish in the Manufacturing of Composites

A modern film can do really alot in order to help you to get very good composite products. Some of the functions a modern film can accomplish today are the following:

to maintain the whole resin content of prepregs in the finished item, reducing so the weight and the defected items;
to give the external look of the composite;
to release easily at the end of the process;
to improve the structural characteristics of composite by compaction of the different layers of prepregs (tubolar elements, rototranslaction process), by applying very strong pressure in the wrapping process;
to improve the structural characteristics by compression during polymerization (tubolar elements, rototranslaction process), achieved by a strong pressure given by an enhanced heat shrinking of the film;
in debulking, effectively compact the various layers of prepreg and avoid delamination phenomena between the various layers;
to higher processing temperatures (either to reduce processing times, or to use peculiar termosetting resins, or to get an even and perfect polymerization of the resin in case of an important thickness of composite’s walls), acting as an heat shield during polymerization;
to protect the mould’s walls and avoid the cleaning after every cycle or the sanding.

The List of High Tech Release Film available for the Manufacturing of Composites

We have now a range of a dozen of films specifically designed for the production of composites. All our films for the production of composites are made according to company specifications, with a precise recipe as regards the raw materials used, and peculiar manufacturing processes of the films, that determine mechanical resistance, temperature withstand, and the other physical characteristics of the film. The list of the presently commonly used products is the following:

Cellofan P45 and P60 in reels;
Polipropilene Speciale in reels;
Bifilm in reels;
Polipropilene Alto Modulo in reels and sheets;
Film 90 in reels and monofolded reels;
Polipropilene Superstiro in reels:
Polipropilene Superplanare in reels, small reels for manual wrapping and sheets;
Polipropilene Satinato in reels and sheets;
Poliestere Film in reels;
Polipropilene Superstiro Calandrato in reels and sheets;
Polipropilene Deformabile in reels and sheets;
Polipropilene Graffiato in reels and sheets.

Other films are not in the list, either because at the moment they are still in the introduction phase or because we have exclusive supply agreements or non disclosure agreements with some customers.

Registered users can receive technical data sheet and prices on request. We kindly ask you either to call us at +39.0438492335, or to fax at +39.0438492365 or to send us an email at info@aperuzza.com.

Besides written papers in our opinion it is much more important to understand the real use of the films. Today the major part of our customers are using a combination of two or more films. This is not made for commercial purposes (to sell more films) but because in this way production process is carried out in controlled (standard) conditions, composites structures are improved, the number of defected items is drastically reduced and much more.

We cannot explain this in a short web page, nor in any written document as well, for the simple reason that this is a tailored made process, done on the specific needs and processing procedures of each customer.

If you have some problem or you want to get the best out of your composites and of our films again we ask you to contact us. We can make over the telephone consultacy (in english and in italian) and we can send samples of selected films in every part of the world.

For further infomations write, phone, send an email at:

A. Peruzza S.r.l. – via Portelle 1 – 31010 Mareno di Piave – Tv – Italia
Telefono: (int+ 39) 0438 492335. Telefax: (int+ 39) 0438 492365

Email: info@aperuzza.com

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