Institute of New Carbon Materials and Technologies
MATERIALS
PARTS AND TOOLING
EQUIPMENT
TESTING
Our markets
Aviation and space
UAV and drones
Transport
Automotive and tuning
Sport
Medical devices
Marine
Building and construction
Equipment
Composite Materials
It combines high strength, low weight, and resilience in extreme environments. All materials are engineered to meet the demands of mission-critical industries and undergo rigorous quality control at every stage.
Resins
Polymer resins for vacuum infusion and RTM
Tooling materials
Low-viscosity resins and carbon fabrics for large-scale tooling production
Pastes, adhesives and films
For bonding honeycomb, metal and composite structures
Carbon fabrics and tapes
For classic and automated lay-up
Fabrics with binder for automated cutting
Fabrics with binder for automated cutting
Prepregs
Based on carbon and glass fabrics
For service temperatures up to +350 C
For service temperatures up to +350 C
Repair materials
Adhesives and pastes for repair of composite and metal structures
Composite tooling
The accuracy, surface finish, and repeatability of a composite part are directly dependent on the quality of the molding tools used in its production.
Products and Services
Master models
Before a final composite part can be produced, the manufacturing process depending on the part's complexity requires the creation of various types of specialized tooling. This includes the molding tools themselves, the production of which always begins with a master model.
Composite parts
For end use components, achieving the required set of physical and mechanical properties is paramount. Our team of experienced engineers and scientists specializes in defining and ensuring these critical parameters.
Warpage compensation
A significant challenge in manufacturing composite parts is deviation from the nominal geometry — known as warpage. This phenomenon is caused by resin shrinkage during cure and the highly anisotropic nature of composite materials.
We make tooing with our proprietary warpage distortion compensation to ensure high accuracy of the parts.
We make tooing with our proprietary warpage distortion compensation to ensure high accuracy of the parts.
Machining services
Our company provides machining services for both composite tooling and finished parts.
Equipment manufacturing
INCMaT specializes in the design and manufacture of prepreg production lines (1200 mm working width), utilizing resin impregnation technology. The integrated system includes a resin film application unit and a laminating unit, where the film is transferred onto the reinforcement fabric to create the prepreg. The laminating section supports single-sided or double-sided film application.
Edge trimming, precision slitting
Precision strip slitting module
- Slitting tolerance: ±0.05 mm
- Rapid strip width change
- Disc-type pneumatic knives and a driven shaft with bottom knives
Universal station for cross-cutting and heat sealing
- Vacuum table for material hold-down
- Max. web width: 400 mm
- Bonding of materials with a process temperature up to 400 °C
Composite parts and tooling design
Services for equipment development, design, engineering analysis, and automation. Given that these services require expertise from various fields such as mechanical engineering, electrical engineering, information technology, and chemical engineering, our design bureau employs a multidisciplinary team of specialists. This includes graduates of the Chemistry Department of Moscow State University, holders of Candidate of Sciences (Ph.D.) degrees in Technical Sciences, and Automation and Control Systems Engineers.
Design of automated control systems
To ensure continuous operation of production lines and maintain material quality, equipment automation is essential. We provide comprehensive automation services, which include the following stages:
- Project development and equipment selection
- Development of control cabinet wiring diagrams and release of associated design documentation
- PLC (Programmable Logic Controller) software development
- Development of Human-Machine Interfaces (HMI)
- Creation of operational instructions
Engineering analysis: load analysis, thermal calculations, and precision calenders.
Our design bureau performs load analysis and thermal calculations. Calenders – presses with horizontal rolls used for both heating and cooling – are employed for transferring and applying binding materials to technical papers or fabrics. Furthermore, calenders are used for processing materials such as plastics, rubber, and textiles.
We have extensive experience in the design, engineering analysis, and manufacturing of precision calenders with an accuracy of up to 0.002 mm. This includes the development of surrounding structures – frames, guides, etc.
Our design bureau performs load analysis and thermal calculations. Calenders – presses with horizontal rolls used for both heating and cooling – are employed for transferring and applying binding materials to technical papers or fabrics. Furthermore, calenders are used for processing materials such as plastics, rubber, and textiles.
We have extensive experience in the design, engineering analysis, and manufacturing of precision calenders with an accuracy of up to 0.002 mm. This includes the development of surrounding structures – frames, guides, etc.
Auxiliary and other equipment
Mobile tilter
- Mobile upending device
- Lifting and tilting of drums with a capacity of up to 200 L
Stationary Tilter
- Automated lifting and tilting of a 300-litre mixing bowl
- Smooth lifting and tilting ensure even drainage of the container's contents
- Lifting capacity: 900 kg
High-temperature reinforcement of fabrics with polyamide nonwovens
Powder coating of fabrics with thermoplastics
Binder Application Module
This module is designed for the metering and application of powder onto the material. A metering roller ensures a uniform coating. To confine the application zone, the hopper is fitted with adjustable side plates. Additionally, agitators are installed inside the hopper to prevent powder caking and agglomeration.
Impregnation baths for fabrics
- Attachable bath
- Saturation of the tape in a bath using specific formulations
- Forced solution circulation
- Automatic squeeze roller at the outlet
Winders and unwinders
Automated two-station winding module for binder-Impregnated carbon fiber tape.
- Uniform material winding.
- Simultaneous winding on two winding stations.
- Linear speed adjustment (line speed control) with diameter compensation.
- Automatic stop of the winding stations in the "up" position for pneumatic shaft ejection/removal.
Unwind stand for 600 mm
- Preset constant web tension
- Ширина материала до 600 мм
Graphite foil winding module
- Winding the material onto one of two winding stations at a constant linear speed, with diameter compensation.
- Automatic servo drive stop in the shaft removal position.
- Clamping of the material tail end to the core
- Automatic start of the winding station servo drive after the material is secured.
Web edge guiding during rewinding
- Unwinder with automatic edge guide
- Fixed web edge position at the line infeed
- Preset constant web tension during line operation
- Roll width: 400 - 1200 mm
- Automatic return to the central traverse position upon shaft release
Film laminating line
Designed for applying an epoxy resin coating (film) onto a moving paper substrate using a rubber-coated roller
Characteristics
Lamination line
It transfers epoxy resin from a carrier onto the fabric and saturates it. The film can be applied to one or both sides. Furthermore, the line laminates the adhesive side and winds the finished prepreg into rolls.
Characteristics
Composite tooling
The dimensional accuracy, surface finish, and repeatability of a composite part are directly dependent on the quality of the molding tools used in its production.
Master models
Before a finished composite part can be produced, the manufacturing process depending on the part's complexity requires the creation of various types of specialized tooling. This includes the molding tools themselves, the production of which always begins with a master model.
Composite products
For end use components, achieving the required set of physical and mechanical properties is paramount. Our team of experienced engineers and scientists specializes in defining and ensuring these critical parameters.
Warpage calculation
A significant challenge in manufacturing composite parts is dimensional deviation from the nominal geometry — known as warpage. This phenomenon is caused by resin shrinkage during cure and the highly anisotropic nature of composite materials.
Machining services
Our company provides machining services for both composite tooling and finished parts.
01
Development of high-temperature polymer matrices
02
Development of materials for high-temperature vacuum Infusion and RTM
03
Development and optimization of carbon-carbon composite manufacturing technology
04
Advancement of carbon fiber textile processing technologies
05
Characterization of polymer matrix and composite material properties
06
Development of carbon fiber reinforced polymer (CFRP) part manufacturing technology and prototyping
07
Surface modification of carbon fibers
08
Modeling of temperature gradients arising during the polymerization of composite materials
Main directions
R&D
We are developing composite materials for our in-house production. Currently, numerous existing metal structures can be replaced with composite structures, achieving simultaneous functional improvements such as weight reduction and increased stiffness.
01
Development of high-temperature polymer matrices
02
Development of materials for high-temperature vacuum Infusion and RTM
03
Development and optimization of carbon-carbon composite manufacturing technology
04
Advancement of carbon fiber textile processing technologies
05
Characterization of polymer matrix and composite material properties
06
Development of carbon fiber reinforced polymer (CFRP) part manufacturing technology and prototyping
07
Surface modification of carbon fibers
08
Modeling of temperature gradients arising during the polymerization of composite materials
Composite materials testing
Our company operates an extensive fleet of research equipment for mechanical properties testing, thermophysical properties measurement, and materials microstructure analysis. Testing is performed in accordance with national and international standards, or using proprietary procedures specifically developed to address complex and non-routine challenges.
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