Fill Robot Layup | © Fill
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The flexible production cell

Reliable manufacturing of preforms is the basis for high-quality composite leaf-spring components. The key criteria for this are placement accuracy, system performance, and laying rate – all accompanied by high levels of process stability and system availability. 

For this manufacturing technology, Fill has developed a flexible production cell for laying and preforming pre-impregnated composite materials (prepregs)  
The priority here is maximum flexibility based on simple programming plus rapid component type changes, thereby guaranteeing constant capacity utilization of the machine. 

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Fill Machine Engineering Rupertsberger Wilhelm | © Fill
Wilhelm Rupertsberger Head of Competence Center Plastics
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The concept

From a roll of raw material, a linear unit removes individual strips in predefined lengths and places them on a provisioning table. From there, two robots grip the individual cuttings and manipulate them to the draping fixture, where they are laid down. A pressure roller located on a third robot then executes the appropriate consolidation process. 

Layer length and the number of layers are freely selectable and can be adjusted accordingly per spring, if required, due to an integrated weighing system in the draping fixture.  


  • Flexible process design for different component geometries   
  • Short set-up times when changing tools   

  • Individually adjustable pre-consolidation steps  

  • Raw material changeover in the non-productive time  

  • Cooling system for controlling the material processing temperature  


Input material: Rolled material (mm)

width: 50 to 100 

Max. roll weight (kg)


Layer length (mm)

150 to 1,500

Max. component curvature (mm)


Electronic controller

Siemens Simatic S7-1500 



Special sizes

on request

Image processing system for residual film detection on the material 

Web edge guidance of the decoiling fixture 

Integration of provided press systems 

Technical specifications subject to change .

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