Blank Making - 'Roll-wrapping'
Kilwell Fibretube began constructing tubular composites in 1968 in Rotorua, New Zealand - mostly for the fishing rod industry. Today the company makes hi-tech tubes for over 20 different applications including marine construction and fittings, rowing and canoeing and numerous sporting and industrial applications.
We use a "Roll-Wrapping" process to produce tubing of the highest possible standard. Our unique pressure wrapping system, developed after years of exhaustive R&D, ensures hi-tech composite tubing of the ultimate in strength and stiffness to weight ratios.
With the latest in space age materials like high modulus carbon fibre, Kevlar and the 5,200 square meter factory in Rotorua the future looks bright for Kilwell... and you.
The Process
Roll wrapping has many advantages over other methods of tube production and Kilwell Fibretube have enhanced and developed production to make tubing lighter, stiffer and stronger than previously possible.
Pre preg raw materials, with strictly controlled resin content, are the first step in consistent production. Fibretube's exclusive pressure rolling and wrapping systems developed after many years of R&D, produce tube of unequalled performance.
Step 1.
Rolls of 'Pre Preg' (pre impregnated with resin) carbon or glass fibre are ready to be cut. The Pre Preg is stored in the freezer to keep the resin fresh. |
Step 2.
The Pre Preg is cut into specific shapes known as patterns. Tube design is very much effected by the 'cut of the cloth'. |
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Step 3.
Our computer controlled plotting machine cuts Pre Preg to the highest degree of accuracy. |
Step 4.
Mandrels (internal moulds) of specific, precise diameter and or taper rate form the tubes internal profile. The cut patterns will be wrapped tightly over these. |
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Step 5.
"Tacking" is the process where the edges of the cut patterns are adhered to the mandrel. It is often done with the aid of an iron (and requires a steady hand). Some of our fishing rod mandrels are under 1mm in diameter!  |
Step 6.
The mandrel, with cloth attached, is then Pressure rolled between the plates of a special table. |
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Step 7.
The rolled tube is then wrapped with a heat shrink cellophane for added pressure. The heat shrink produces the fine 'rat tail' look you'll see in our unsanded tubes. |
Step 8.
The rolled and wrapped mandrels are then loaded into an oven to be cured or baked. |
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Step 9.
Hot, cured tubing, still on the mandrels are removed from the oven ...  |
Step 10.
... the mandrel is drawn out leaving the hollow tubular blank almost ready to be used. The mandrels are used again and again.  |
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Step 11.
The heat shrink tape is removed by blasting with high pressure water and the tube is ready to use. It can be externally ground to size or to allow a paint coating to be applied.  |
Step 12.
An optional two-pot paint provides UV resistance or cosmetic appeal.  |
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Step 13.
Finished tubes - ready for despatch.  |
