Reverie is Full ISO9001 approved and has a range of composite manufacturing facilities with 10,000 Sq Ft available to provide a composite product that has been optimised throughout the design, development and fabrication process. Our site facilities and processes are listed below:
Reverie is able to produce scale or full size models of parts by hand or, for more complex parts, by CNC machining using our Thermwood M67 5 Axis CNC Router (X1524 x Y1524 x Z609 mm) or Hass VF4 CNC (X1270 x Y508 x Z635 mm) on site. These models can be used as a pattern to produce composite mould tools or simply for proof of concept. Alternatively, when dimensional tolerance is paramount, a tool can be machined directly from aluminium with correction made for differences in thermal expansion between the composite part and aluminium tool. Perfectly flat and level surface floor plates with a total area of 9m2 allows accurate measurement of any object up to the size of a large racing car.
Reverie will digitise templates or unfold complex 3D solid models where CAD is available to generate 3D flat patterns to be put into Sigmanest software and be used to generate efficient and correct ply lay-ups to be CNC cut on one of our two CNC kit cutting tables with oscillating knifes (small: 2650x2265mm and large: 3500mmx2265mm). All Materials used are issued to the correct works orders within our MRP software, so full pre-preg batch material traceability is also ensured. Raw materials are kept in a climate controlled freezer room at -18c and all materials are correctly thawed before use and refrozen after use to ensure material lifes are not compromised.
In the 880Sq ft clean room the manufacturing process begins. Sales orders that have been inputted to the computerised MRP system appear on the clean room work station and visual planning in priority order. Kits will have been pre-cut and materials pre assigned and logged for traceability. The laminator can then focus on laminating the right issue part in the right issue mould tool, plys and vacuum bagging are cross checked by another employee of the same or higher skill level. Generally speaking parts that are oven cured at 1 atmosphere pressure suffer a reduction in mechanical properties of about 15%, increased weight by up to 10% and don't have the same of surface finish when compared with those that are autoclave cured.
An autoclave is effectively a pressurised oven allowing the curing of parts whilst under vacuum at up to 100PSI to ensure excellent consolidation of the finished part. We have two autoclaves of differing sizes, having the advantage of allowing the optimum size of clave to be chosen for a particular job, ensuring the best quality part and the lowest running costs. We are also able to offer autoclave pressure and temperature conditions logging to confirm the cure schedule.
Large Clave: 100psi 230'c capability (1150mm diameter x 3750mm length x 800mm)
Small Clave: 100psi 300'c capability (480mm diameter x 750mm length x 380mm)
Reverie has a number of different ovens located in various areas of the factory. They are used for mould preparation, low cost vacuum-only curing of parts and post curing of tools, patterns or components. Generally speaking, parts that are oven cured at 1 atmosphere pressure suffer a reduction in mechanical properties of about 15%, increased weight by up to 10% and dont have the same quality of surface finish when compared with those that are autoclave cured.
After cure, the component is broken out of the mould and transferred to the Trim Shop. Here, Reverie's experienced fettlers remove any excess material and resin flash to EOP scribe lines or using jigs and fixtures to prepare the part for final fitting through the addition of holes etc. In the fitting shop, inserts, fasteners and other items are assembled to the moulding to make the finished part. This will then be prepared as required, either highly polished or rubbed down matte ready for painting. We also now have an onsite Vapour Matt vapour blaster, for preparing carbon fibre for paint or preparing alloy inserts prior to secondary cold bonding.
We are fully ISO9001 approved and have Openmind Hypermill and Hypercad software to ensure precise accuracy of machining of tooling block, aluminium, carbon fibre and glass fibre on our two verticle CNC Machines.
Reverie has its own paint booth and preperation rooms to prepair parts to receive a high quality finish.
Reverie has a full set of calibrated measuring equipment including a FARO FUSION Inspection arm with powerful Geomagic Probe software to compare parts, moulds or patterns to 3D CAD models. This ensures that all parts leave the factory to the correct specification and required quality. Full inspection reports and certificates of conformance can be produced for each part or samples from batches if required.