Process for production of metal-wood composite profiles

The process technology enables the production of high-performance metal-wood composite profiles by integrating wood core sheathing and specifically modified wood core materials into a single, energy-efficient manufacturing operation.

Challenge

Composite structures combine properties of individual materials to provide advantageous property profiles, versatile performance in application and economic advantages in the final product. One example is the combination of metal with wood: while metallic materials have comparatively good electrical and thermal conductivity, ductility, weather resistance and higher melting points, wood-based materials exhibit lower densities, sustainable components, good (mechanical) machinability and aesthetics. Combining different materials in one product can be challenging, especially when material compatibility is required while maintaining technical versatility and overall production costs. Conventional methods for manufacturing composite materials often involve multiple stages of joining, forming and bonding, which can lead to increased costs, energy consumption and complexity. Hence, more simplified and productive production processes are desired.

Our Solution

The present process technology enables a precise and efficient production of high-performance metal-wood composite profiles with good scaling options. The technology is mainly characterized by integration of wood core sheathing and a specific modification of the core material into a single, energy-efficient production operation, which leads to purely material-mediated property generation and optimization. The production method combines the mechanical advantages of a metal casing with the lightweight and sustainable nature of wood, resulting in robust and dimensionally stable hybrid materials. The production machinery can generate composite structures with desired shapes, but also enhances the internal properties of the wood through specific material modification. The overall product properties can be tuned directly via the production process.