Technology
King Agro

We strive to create products that challenge established paradigms, taking advantage of new technologies and a team of highly specialized professionals committed to our mission.

We specialise in research, design and development.

At King Agro we have spent more than 20 years working in calculating and designing components and structures in Carbon Fiber. We have developed our own applications for Finite Method Analysis, which are verified on dozens of structures every year.    

Annually, we invest 75% of our revenue in the development of manufacturing processes and new products. Our commitment to never-ending improvement is reflected in the processes of vacuum, lamination, autoclave and robot machining, all of which increase the quality of our products.  

We are

design

We are quality

We are manufacturing

Every new product is born from team work. 

The team, composed of specialized engineers and executives, establish the objectives in terms of weight, resistance and features. All options and possible paths are considered, moving forward with various stages of prototypes and design ideas.
Once the design is settled on, a Finite Method Analysis is carried out. This is a computer-generated simulation of the efforts the boom will be subjected to. The efforts are calculated using sophisticated structural calculation software designed specifically for composite materials. Through the simulation, several variables are tested like fiber orientation and number of layers, until the optimal combination is reached.

Once the design is finalized, there are 4 stages to be completed.

1

Prototyping

A prototype is built to assess feasibility and is subjected to destructive testing, and its design optimized.

2

Product Execution Study

the manufacturing process is analyzed and improvements in the design are made with the purpose of speeding up the manufacturing process.

3

Durability testing

A small batch of products are manufactured and tested on the field for approximately six months

4

Production launch

Finally, once all improvements are made, the final stage is reached. The product, thoroughly tested, is now ready to be launched

At King Agro producing trustworthy products is our first priority.  

To reach this goal we employ a Quality Management System that perfectly adapts to the requirements of the Carbon Fiber sector, from the raw material acquisition to the market launch of a new product. Our Control Plan counts with rigorous quality controls from the conception of the product in the design phase all the way through to the delivery of the finished product to the client, and our Quality Control management model is based on Lean Manufacturing, with continuous follow-up indicators, using the DMAIC methodology and the Kaizen system.

We work closely with our providers assuring quality is maintained in all components, new projects, and research and development. At King Agro each manufacturing phase counts with the most advanced quality control instruments, assuring the functional, physical-mechanical and resistant characteristics to outdoor conditions, reaching a product compliant with the highest standards in Quality Control in the Carbon Fiber industry.

The resin with which the Carbon Fiber is impregnated cures at room temperature, which is why it must be stored in freezers with sub-zero temperatures.

The resin with which the Carbon Fiber is impregnated cures at room temperature, which is why it must be stored in freezers with sub-zero temperatures.

The first step in the manufacturing process is cutting the Carbon Fiber sheets according to the required geometry using a CNC plotter. The cut-outs are positioned over the molds (produced at a 5-axis mechanization center), which are then subjected to vacuum so that all air between the Carbon Fiber layers is sucked out, and the sheets are completely compacted. The vacuum pressure is equivalent to an additional pressure bar (10.000 kg/m2).

The mold is then placed in the autoclave where three additional pressure bars are applied, reaching a pressure equivalent to 48 adult elephants stacked vertically. Simultaneously, the temperature inside the autoclave reaches 284°F, enough to fully polymerize the resin.

Holes, cut-outs and edges are then grinded by a CNC WaterJet robot.

The boom is carried through the production line, where the parts are sanded and clear-coated with a polyurethane paint to avoid degradation (yellowing) of the resin. Finally, the boom is dried in a tunnel fitted with infrared lamps.

The Quality Control department is present at all stages of the process, assuring that the parts produced are within predefined tolerances. In order to accomplish this, measuring devices like the FaroArm are used.