Dencam Profile Brochure

innovative tooling solutions

Wind

Marine

3D Modelling

2 Dencam Composite - Your supplier of turnkey tooling solutions

www.dencam.com

supplier of turnkey tooling solutions

Based on years of experience in the composite and fiberglass industry, we pride ourselves of being the leading supplier of high quality, cost-effective tooling solutions for various composite industries.

from first concept to finished part, we cover the entire production process when manufacturing our custo-mers’ production tools and can supply master plugs, moulds, direct moulds and models together with all the necessary tooling.

in order for us to deliver first class turnkey solutions and constantly develop new production methods and

materials, we welcome innovative and dynamic thin-king and keep a close dialogue with our customers. our iso 9001 certification ensures that our customers’ de-mands for assurance and continuous improvement are constantly met.

the following pages of this brochure take you through our range of high quality tooling solutions. should you be left with any unanswered questions, please do not hesitate to contact us.

Best regards, Ceo, Jesper andersen

A consistent level of quality, delivery on time and according to budget are key objectives to us. Our dedicated team of employees serves the needs of

your company with one purpose in mind - satisfied customers.

Dencam Composite - Your supplier of turnkey tooling solutions

www.dencam.com

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“While tooling plays a central role in the highly cost-conscious and competitive composite industry and the future lies with innovative solutions driving down costs and time to market, we are in Dencam always looking to expand our busi-ness scope and broaden our minds to remain a significant player in the compo-

site industry.”

WinD page 4

Marine page 10

3D MoDellingpage 14


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aCCurate anD DuraBle tooling for WinD turBine BlaDes

With wind turbines getting bigger and bigger, the need for large scale blade tooling is increasing. in Dencam, we have the tooling, know-how and competences to make extremely accurate composite plugs and moulds matching our customers’ specifications.

With years of experience in plug and mould production for turbine blades and a highly competent staff, Dencam offers not only single services but can also assist every step of the way from design and CnC milling of plug to mould produc-tion, prototyping and commissioning. Besides, if necessary our skilled and experienced service team can train our cus-tomers’ staff either before commissioning at Dencam’s facilities or on-site at our customers.

“With years of experience in the fiberglass and composite industry, Dencam is leading supplier of high quality, cost-effective tooling solutions for the global wind industry.”

large sCale 3D Milling of plugs

When producing plugs for manufacture of blade moulds, we ensure a quick and economical solution - from prototyping to delivery of the fi-nished plug. our plugs are made with extreme precision on state-of-the-art CnC milling machines specially designed to large objects. Dependent on size, we work with tolerances as low as +/- 0.1 mm.

We offer plugs in different materials and different price ranges depen-dent on customer wishes and requirements. the sandwich construction ensures a solid and rigid structure and the substructure is designed to accommodate individual loads and specifications of the plug.

MoDular teChnique

no plug is too big for us to handle. the plugs can be produced in sections and later assembled with guaranteed symmetry and impressive finish.this unique modular technique designed to fit into standard 20” & 40” containers enables us to meet the demands for increasingly larger blades, optimize handling and storage and reduce logistic costs for road and sea transport.

WinD


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neW high perforManCe plug

as the only supplier in the wind industry, Dencam now provides master plugs in glass fibre. the plug is cor-rosion and weather resistant, requires a minimum of maintenance and can be stored outside if necessary.

as opposed to traditional plugs which can sustain only a certain number of prints, the glass fibre plug can en-dure multiple prints and offers easy and smooth de-mouldings with no risk of cracks in the top surface layer.

the finishing touChes

an electrical heating system can be integrated in the plug making optimal control of temperatures during infusion and curing possible. integrated heat sensors facilitate measuring of plug temperature during later mould production.

By means of milling, grinding, painting and polish-ing, the surface reaches a high finish level ensuring a smooth and clean plug surface.

as part of Dencam’s quality control, the plug is checked manually and laser measured to control critical points on the surface and to ensure the highest degree of pre-cision. to maintain the high level of quality all the way to installation at our customers’ facility, shock sensors are installed to monitor the movement of the plug dur-ing transport.

• great strength compared to its weight

• far better temperature constancy

• a lot more prints

• Corrosion and weather resistant

• Minimum maintenance

• quick preparation between demouldings


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supplier to large WinD inDustry players

high quality BlaDe MoulDs

Concurrently with the development within large off-shore wind turbines and the increasing need for large scale blade moulds, Dencam offers the tooling, know-how and competences to make extremely accurate composite moulds matching our customers’ specifica-tions. our moulds are durable and simple in operation and their compact design makes them easy to relocate and set up anywhere in the world.

WinD

laser traCking

to stay within the world elite in design and production of plugs and moulds, Dencam has implemented a wide range of tests and measure-ments to check geometry and contours of any milled surface. With several years of hands-on experience, our staff is highly skilled and ca-pable of performing various laser tracking tasks including training and support.

sCope of supply

• design of substructure including feM analysis• design and delivery of power hinges• hydraulic clamp system• tooling • laser tracking control of the surface• commissioning.


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DireCt MoulD teChnology

for site specific turbine blades and one-offs, where a small series of products is required with very short lead-time, Den-cam is able to produce direct moulds thereby avoiding the cost-intensive and time-consuming master plug normally re-presenting the start of a new mould project. the milling process and the materials used in the direct moulds are the same as with traditional moulds. our state-of-the-art CnC milling machines work within tolerances as low as +/- 0.1 mm.

the moulds are modular built making subsequent modifications of e.g. root, mid and tip section of the blade easy. the splits can be done crosswise as well as lengthwise dependent on size and specific customer needs. When cracks and other imperfections appear in the surface as a result of normal wear and tear, the mould’s service life can easily be pro-longed by means of Dencam’s milling machines.

ManufaCturing proCess

• perforated steel plates are welded on steel frames• foam is applied and milled • first layer of glass fiber epoxy laminate is applied • heat spread layer for the heating system is applied• second layer of epoxy glass fiber laminate is

vacuum infused • Curing of surface• CnC milling to final measurements• sanding and preparation of the surface• top coating is applied • Dry sanding of milled surface.

siMplifiCation of proDuCtion proCess

to simplify the production process, we have developed special methods for construction of both heating and vacuum systems. the vacuum system is part of the standard mould package and integrated according to customer specifications as either a single or double vacuum system.


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In 2013, the new Danish Maritime Museum was inaugurated.The museum showcases numerous exhibitions tel-ling the story of Denmark’s maritime heritage. One attraction is the majestic 8 meter long model of the world’s lar-gest container ship, the Triple-E vessel, Mærsk Mc-Kinney Møller, which was produced and delivered by Andresen & Meyer.

Based on 2D files, Dencam did the 3D modelling, the downsizing and the milling of the hull model for this majestic 8 meter long model.


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MetiCously shapeD tooling for luxurious Boats anD yaChts

Whether you need a one-off direct mould for prototyping or a high-quality plug for continuous mould production, our high speed 5-axis CnC milling machines offer great advantages in terms of time reductions and accuracy of fit.

Choosing Dencam’s CnC milling expertise for your next yacht or boat tooling, brings you ahead of competition and gives you a wide range of possibilities in terms of quality, size and complexity.

Cutting edge technology, experienced staff and years of accumulated knowledge offer our customers high-quality products for boats and luxurious yachts. through the years, plugs and milled moulds up to 140 ft. have been realised.

our constant focus on product development and optimi-sation enables us to provide our customers with a wide range of cost-effective, durable and extremely accurate solutions in all shapes and sizes.

Marine


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unpreCeDenteD aCCuraCy

With three five-axis CnC machines, the largest one measuring 52mx8mx4m, we have a host of opportuni-ties when producing plugs and direct moulds for yachts and boats. our machines are especially well suited to large, custom or semi-series projects where tool ma-king would normally be a cost-intensive and time-con-suming step.

Besides the obvious cost and time reduction benefits, CnC milling offers a clear advantage when it comes to accuracy of fit. the accuracy of our milling machines is 0.5mm over the total length of the machines, but can be accurate down to 0.1mm locally.

size is not an issue

We can handle almost any size and shape when mil-ling plugs and moulds on our advanced CnC machines. We mainly mill in materials such as wood, eps, pu and epoxy but can also cut in rough surfaces such as glass fibre.

no task is too CoMplex

everything from hulls, decks, internals to complex su-per structures for high quality boats and yachts are me-ticulously shaped on our CnC machines. We consider no task too complex. for smaller components with fine details we have a machine that is excellent for this purpose with stiffer rail guidance and a more powerful spindle.


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Marine

DireCt one-off MoulD

our primary focus in the marine industry is direct one-off components providing savings in both time and money. for pro-jects where a minimum of one print is needed or where the timetable is extremely tight, it makes perfect sense to skip the master plug and produce the mould directly on our advanced machines. you can tailor your mould to fit the specific needs of your project and save time and money.

easy hanDling of large oBJeCts

to meet the logistic challenges related to plugs and moulds for today’s large luxurious yachts, we have developed a tech-nique where we can manufacture the product in sections thereby facilitating easy handling and drive down costs for road and sea transport.

accuracy of fit permeates all of Dencam’s production processes - also when manufactured in sections. all of our pro-ducts are characterized by extremely fine tolerances removing the need for later adjustments and providing a much bet-ter quality of the end product.

innovative tooling solutions

high perforManCe glass plugs

as the only supplier in the marine industry, Dencam has launched an alternative to the traditional mas-ter plug. Made in glass fiber, this new type of plug offers a quality and durability that goes way be-yond that of former constructions.

the plug can endure an almost endless number of prints, is weather-resistant and easy to prepare be-tween demouldings.

the glass fibre composition makes this plug a strong alternative to traditional plug manufactu-ring, though still being a lightweight solution.


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optiMise your next Boat proJeCt

in Dencam, we can adjust every little detail to match our customers’ requests for lead time, costs and roi.

you can be confident that Dencam is the right match if you are looking for a flexible and reliable supplier offering;

• potential savings in both time and money

• high quality and product optimization

• a wide range of plug and mould solutions

• advanced CnC milling services where any size and shape can be handled.


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Dencam has several years of experience within mould building, milling of models and composite materials in general. We offer customized solutions within mo-delling and production and handle all sizes, shapes and levels of details.

With our 5-axis CnC milling machines, we can mill in materials such as: styrofoam, foams, pastes, woods, grp, carbon fiber, aluminium etc.

Dencam provides the freedom of form and shape and has great experience with large scale projects. We pro-duce everything from models, prototypes, plugs and moulds to direct moulds all originating from digital 2D and 3D designs. With us, you get tailor-made solutions always matching specifications as well as expecta-tions.

turning Design into reality

3D MoDelling

Based on 2D files, Dencam did the 3D modelling, the downsizing and the milling of the hull model for this majestic 8 meter long model of the world’s largest con-tainer ship, the Triple-E vessel, Mærsk Mc-Kinney Møller. The scale model was produced and delivered by Andresen & Meyer and is today displayed in the Danish Maritime Museum.

our models are built of lightweight materials facilita-ting easy handling and adjustments. Mock-ups in any desired dimension provide the opportunity to assess and evaluate a design before actual manufacturing takes place.

Dencam has great experience in creating special one-off projects for prototypes and smaller production set-ups. We have taken a key role in the development and mingle without a doubt with the world elite.

our CnC production can cater for almost all sizes and shapes and embraces a large variety of tasks:

• art and sculpture

• Construction and architecture

• exhibitions and displays

• prototyping


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This boat model, milled by Den-cam in abachi wood was used by our customer in a test to measure the boat’s wave resistance.

In 2011, Tivoli Gardens erected the Russian St. Basil’s Cathedral featuring a 21 meter tall tower with onion domes and a carillon. Dencam was responsible for the CNC milling of these beautiful domes, produced by Danish Skou Gruppen.

“Providing freedom of form and shape and realising dreams.”Ceo of Dencam Composite, Jesper andersen

[email protected] www.dencam.com +45 5373 0035

Dencam Composite Mørkebjergvej 65600 faaborgDenmark

Dencam Mould factory nørrevang 19, nr. lyndelse5792 ÅrslevDenmark

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