We produce components from a wide variety of plastics especially for military applications.
After 45 years of working alongside the defense industry, we have learned what really counts.
POTENTIAL
APPLICATIONS
PERFORMANCE
The potential of defense technology
Plastics offer numerous advantages for use in defense technology. Outstanding strength combined with minimal weight is just one of these advantages. This text explains the reasons why the use of lightweight components made of carbon fiber-reinforced plastic (CFRP) in defence technology is worthwhile.
Time and again, groundbreaking technologies emerge that have the potential to fundamentally change the defence industry. After years of qualification processes, CFRP is one of these innovative materials. Careful selection of the right material and an understanding of the possible combinations of these materials are essential prerequisites for efficient and economical production in the defense industry.
Applications in defense technology
Launcher systems (launch tube)
Launcher systems that rely on carbon composites herald an exciting future. These cutting-edge technologies not only promise to drastically reduce weight – they also mean that more load can be carried and more efficiently than ever before. By using lightweight yet extremely strong carbon-reinforced plastics, they increase performance and confidently meet the demands of modern warfare.
Floating body
CFRP in combination with polyurethane foam or epoxy foam enables the production of extremely lightweight floats . This makes it possible for emergency crews to assemble and disassemble these floats on military vehicles by hand in just a few minutes. This enables extremely fast deployment in water. The floats can be removed just as quickly during the subsequent landing operation. As these floats are not hollow bodies, it is also easier to compensate for the ingress of foreign objects, for example through shelling. The buoyancy of the vehicle is therefore hardly impaired. In this way, military vehicles become amphibious vehicles and enable combat troops to cross water quickly and safely. Mobile equipment such as power generators, containers or housings for communication systems can also be designed to be buoyant.
Military equipment
Difficult, confusing terrain as well as extreme climatic conditions demand everything from emergency forces. Weight-saving material solutions in the equipment of the emergency services can significantly increase the mobility and performance of soldiers.
Vision systems, radios, rucksacks or entrenching equipment are examples of the equipment that a soldier carries with him. The use of lightweight components for this equipment makes it possible to reduce the weight to be transported and thus ensures less physical strain on the soldier.
Exoskeletons
Exoskeletons and an innovative mixture of CFRP and foam, whether polyurethane or epoxy, open up new possibilities for extremely lightweight buoyancy aids. Thanks to this technology, emergency teams can attach or remove such aids to or from military vehicles with their own hands in just a few minutes. This makes it possible to take to the water at lightning speed. The aids can be removed again just as quickly for landing operations. These buoyancy aids are solid, not hollow, which means they can better withstand damage, even from gunfire. This means that the floating capacity of the vehicle remains almost unaffected. Military vehicles are thus transformed into amphibious devices that allow troops to cross waters quickly and safely. Mobile equipment such as power generators, containers or communication equipment can also be made buoyant.
Military infrastructure
Worldwide operations and a wide variety of scenarios require flexible components for military infrastructure. Water tanks, cisterns, fuel tanks and mast systems are just a few examples of applications that are preferably made from lightweight materials.
Our core competencies include specialist knowledge and the ability to carry out on-site repairs or services in highly sensitive areas.
The refurbishment of containers or components made of any plastic or fiber composite material is carried out using vacuum infusion lamination, bonding or welding, depending on the type of damage.
Mobile RIM systems can also be used to restore or protect insulation or oxidizing metal structures (e.g. pipes).
Hi2One protective coatings are used to seal or renovate/repair roofs, tanks and concrete basins. This technology is unique due to the wide range of possible applications. Safety and durability are guaranteed even under the most adverse environmental influences and aggressive media.
Hi2One protects against friction, stone chipping, flying gravel, moisture, chemicals and increases service life. No cracking – no flaking
Mobile structures and enclosures (racks)
The success of a mission largely depends on communication. The modern information technology used by land forces is becoming increasingly digitalized. As a result, the scope of mobile equipment is also increasing.
The success of a mission stands and falls with good communication. Today, the technology used to provide information to land forces is becoming increasingly digital. As a result, the amount of mobile equipment they have to take with them is constantly increasing, which also means an increase in the weight they have to carry. Racks, housings and transport boxes made of carbon make mobility much easier and provide the right protection. Carbon can also be used to achieve a high level of shielding performance over a wide frequency range. The ultimate combination of strength, weight and shielding protection is therefore only possible with carbon fiber composite solutions.
Special area of military vehicles
With decades of expertise in the production of components made of innovative fiber composites and plastics, as well as a wealth of experience in the implementation of prototypes and small series for the defense industry, we are at your side in both design and production. You can play it safe with us, because we manufacture to the highest quality standards and have in-depth knowledge of defense technology standards (STANAG)
STRUCTURAL PARTS
BODYWORK
ELASTIC PARTS
Structural components made of CFRP (carbon)
Structural parts made of CFRP (carbon fiber reinforced plastic) impress with their outstanding strength and extremely low weight. This unique combination gives engineers and designers the opportunity to create products that are both robust and durable as well as enabling a significant reduction in the weight of assemblies and vehicles. They therefore make a significant contribution to increasing the efficiency and performance of modern technologies.
Another unmistakable advantage of structural parts made of CFRP is their resistance to chemical influences and their excellent corrosion resistance. This makes them particularly attractive for use in extreme conditions where parts are exposed to high temperatures and pressure changes
GRP repairs and assembly
Aggressive chemical environments, extreme climatic conditions and high salt content pose considerable challenges for conventional materials.
Metallic materials in particular quickly reach their performance limits in maritime or tropical regions. The aspect of weight reduction is also becoming increasingly important. In addition to carbon fiber reinforced plastic (CFRP), glass fiber reinforced plastic (GFRP) is increasingly being used. Support systems, viewing platforms, water tanks, transmission masts, containers, tanks and pontoon bridges are just some of the diverse applications that are realized with GRP. Thanks to their low weight, these structures are relatively easy to assemble and dismantle. In addition, the corrosion resistance, excellent sound insulation and thermal and chemical stability of GRP offer considerable advantages compared to metal solutions in the applications mentioned.
Production of high-tech products for the defense industry
The production of high-tech composite parts involves several key processes that require precise manufacturing and optimization. Composite materials typically consist of a combination of different materials in order to achieve the desired properties such as strength, lightness and resistance.
Here are some steps and considerations that play a role in the production of such parts:
Material selection:
The targeted selection of suitable reinforcement and matrix materials is of central importance in order to optimally fulfill the specific requirements of military applications.
Commonly used materials include carbon fiber, glass fiber, Vectran fibers and aramid fibers, which develop their best possible properties in combination with high-quality resins such as epoxy, polyester or vinyl ester.
Design and construction:
The development of high-performance parts requires the use of advanced CAD software to precisely simulate complex geometries and load scenarios. The design must not only make optimum use of the material properties, but also take manufacturability and cost efficiency into account.
Various production processes are available, such as hand lamination, vacuum infusion, autoclave technology and filament winding, each of which offers different advantages in terms of quality, speed and cost. Hintsteiner Defence has specialized in autoclave technology to ensure the highest quality standards.
Many composite parts require precise post-processing such as trimming, drilling and the application of surface coatings to meet the required specifications.
Our machining center relies on high-precision technologies with environmentally friendly water without emulsions and lubricants, which leads to outstanding results.
These processes require decades of experience, highly qualified specialists and advanced technologies to meet the strict requirements for precision and performance.
Production of plastic components for the defense industry
The defence industry requires highly specialized materials and components, especially when it comes to plastic parts. These must not only be functional and safe, but also have exceptional longevity, as the life cycles of military vehicles often last for decades. It is crucial to select processes and materials that ensure the long-term availability of spare parts even years after original production.
Durable molds and tools
In the defense industry, it is crucial that even small quantities can be produced economically and flexibly. There are special molds and tools that are designed to produce durable plastic components without significantly increasing production costs.
The production of prototypes or small batches must not be an obstacle to the quality and availability of products. State-of-the-art production technologies make it possible to provide spare parts of the required quality even decades later, which is essential in the defense industry.
Integral flexible foam production
Integral flexible foam products are an important part of the production of plastic components. These are used in areas such as joysticks, gear knobs and seat cushions. Armrests and impact protectors are also frequently made from this material.
Integral soft foam not only offers a high level of flexibility and comfort, but also contributes to user safety. These components are indispensable, especially in military applications where comfort and injury protection are required.
Integral rigid foam production
In addition to flexible foam, integral rigid foam also plays a key role in the production of plastic components for the defense industry. Bumpers, instrument panels and cockpit trim parts are often made from this robust material. Rigid foam provides stability and durability, essential properties for military vehicles that are exposed to extreme conditions. Using rigid foam to manufacture covers and door handles helps to optimize overall product performance and durability.
Rotational molding
Another innovative approach in the production of plastic components is rotational molding. This technique is often used for the production of air ducts, floats, mudguards, water tanks and splash water tanks. Rotational molding makes it possible to produce complex geometries and large cavities efficiently and cost-effectively.
The resulting parts are characterized by high stability and low weight, which makes them particularly suitable for use in the defence industry.
Deep drawing
The deep-drawing process produces cladding parts and covers that are characterized by a pre-coloured base material. This enables a wide range of surface variants, from textured to leather graining and transparent components. These parts are not only functional, but also contribute to the aesthetic design of the vehicle interior.
Elastomer components
The production of PU rubber parts in any Shore hardness offers enormous flexibility for the production of elastic supports, seals and molded gaskets. These components are used in areas where high resistance and sealing are required.
GRP molded parts (polyester parts)
The hand lay-up and infusion processes are used to manufacture large GRP molded parts such as truck roofs, engine hoods and cladding for power generators. These materials are known for their strength and durability and contribute to the structural integrity of military vehicles.
PU castings
Polyurethane castings are of particular importance for military applications. They are manufactured in thick-walled, robust designs and offer excellent protection against chemical influences. These properties make them ideal for potting applications in mine detectors or sensitive electronic components.
Polyurea dummies and molds
One innovative area in plastics production is military dummies, which are used to mislead the enemy.
These dummies, whether in the form of turrets or tanks, are made from lightweight materials such as PU foam or polystyrene and then coated with a polyurea skin to increase their resistance.
The textured coating gives the objects the required strength and an extremely robust, impact-resistant surface.
