Wickert presents a new thermoforming press for aircraft structural components

Wickert Machinenbau, a German company producing complex, fully automated systems integrated in its hydraulic presses, launches a new thermoforming press dedicated to the production of aircraft structural components from composite materials.

The machine operates in a semi-automated way, thus allowing reduced operators’ workloads as well as productivity gains of up to 80%, explains Wickert. It encompasses all production steps, from raw part loading and preheating to the actual pressing process and unloading. Once the prepared composite parts fed into the production process, the robot picks up a clamping frame and transports it to the infrared oven – equipped with two heating stations on two levels – for preheating. There, the part is heated to the required processing temperature within two minutes. Only the respective component geometry is preheated. Then, the robot removes the clamping frame with the preheated component from the oven and moves it to the press, where it is positioned. The actual pressing process, which takes about one minute, then takes place, after which the robot removes the part again.

A flexible, semi-automated and customisable process

In addition to productivity gains, the use of an industrial robot with a customisable handling system makes the process more flexible, enabling the manufacture of components of different sizes, up to 1,100 mm in length. Moreover, the use of magnetic clamping plates to fix tools significantly reduces setup times. The flexibility of the system enables operators to change recipes quickly and easily. It also facilitates data logging and the recording of component-specific process data, enabling complete traceability. All this enables to meet the strict requirements of the aviation industry. 

Wickert’s new thermoforming press is suitable for various types of composite materials used to build structural aircraft components, including carbon fibre-reinforced thermoplastics such as polyphenylene sulfide (PPS) and polyetheretherketone (PEEK). 

All presses are modular in design and customised with press forces between 20 and 100,000 kN. 

“The new press technology makes it possible to form components of varying sizes efficiently and with repeatable accuracy. This not only saves time, but also guarantees consistently high product quality,” emphasizes Steve Büchner, deputy marketing manager at Wickert Maschinenbau.

In the future, Wickert plans to offer a manufacturing process in which manual input and output are fully automated. In addition, the company is developing a concept allowing the clamping frame with the component to be positioned in the press at a freely definable angle for certain applications.

Wickert Maschinenbau was a partner of the project of plastic EV battery housing for mass production that won the JEC Composites Innovation Award 2026 in the Automotive ­­– ­Process category, along with the University of Technology of Chemnitz, Mahle International (project coordinator), Formenbau GF, Gerlinger Industries, in2p and Fraunhofer ICT.

Wickert will exhibit at JEC World 2026, in Hall 5, booth K92.

Cover photo: Semi-automated system with WKP 300 thermoforming press with 300 kN pressing force for aircraft structural parts (source: Wickert)