How Tyrolit Increased Efficiency in Composite Processing and Boosted Profitability by 38 %

Processing composite materials presents unique challenges, as conventional tools quickly lose their sharpness and shape, leading to downtime and increased costs. In 2024, Tyrolit tools enabled customers to achieve significant improvements in composite processing.

• 7 min read

Introduction

Low weight, durability, and design flexibility—these qualities define composite materials such as glass, carbon, and aramid fibers, which are becoming increasingly vital across industries. Whether in wind energy, automotive, or aerospace sectors, the demand for lightweight yet highly durable materials is steadily growing. However, processing these innovative materials presents unique challenges, as conventional tools quickly lose their sharpness and shape, leading to downtime and increased costs.

In 2024, Tyrolit tools enabled customers to achieve significant improvements in composite processing, including:

  • 48 % increase in tool life
  • 76 % reduction in labor hours
  • 52 % reduction in process time

Our customers also achieved:

100 % compliance with surface quality standards

using the rZ value

Consistent quality

across entire components

The results:

Higher output with fewer resources and a 38 % increase in profitability in composite processing.

As a global leader in grinding, cutting, drilling, and dressing tools, Tyrolit offers tailored solutions for composite processing that elevate efficiency and quality to new levels. With over 35,000 industrial customers worldwide and a portfolio of more than 8,000 ready-to- hip products, Tyrolit stands as a synonym for innovation and excellence in material processing.

Challenges in Composite Processing

High Tool Wear

The abrasive properties of composites are particularly demanding on tools, leading to rapid wear, frequent tool changes, increased production costs, and more downtime, all of which impact efficiency.

Complex Material Composition

Composites consist of multiple layers that react differently to mechanical forces, requiring specialized techniques to achieve consistent quality and minimize waste.

Stringent Surface Requirements

In industries like aerospace and automotive, flawless surfaces are crucial. Achieving high-quality standards without defects such as micro-cracks is a significant challenge, especially when processing larger components.

Efficiency and Cost Management

The intricate processing of composites involves labor-intensive methods that extend production times and increase costs. Companies must find innovative solutions to enhance efficiency, reduce costs, and maintain high product quality.

Wind Energy

Enhancing Efficiency in Turbine Blade and Mold Processing

Producing wind turbine blades requires meeting stringent demands due to the size and complexity of the components. Tyrolit achieved remarkable results through the use of TY Power Strips in combination with ENABL robots.

Using these technologies, customers increased tool life by 58 %, significantly reducing tool changes and downtime. Labor requirements were drastically cut—by a factor of 50— thanks to automation with ENABL robots, which ensured consistent, precise processing. Simultaneously, process times were reduced by 42 %, leading to substantial production efficiency gains.

+58 %

tool life

-50x reduction

in labor requirements

-42 %

process time

+38 %

in profitability

Particularly in turbine blade processing, consistent high surface quality across the entire component was achieved. This consistent quality was crucial for process reliability and boosted output significantly. Additionally, Tyrolit tools reduced vibrations and dust generation, leading to improved working conditions and more environmentally friendly processes.

Shipbuilding

High-Precision and Efficient Hull and Underwater Structure Processing

In the marine industry, especially in producing boat hulls and underwater structures, consistent surface quality is critical to minimize water resistance and ensure longevity.

Tyrolit enabled customers to increase tool life by 48 % and reduce labor requirements by a factor of 5. The implementation of TY POWER hand tools not only replaced traditional random orbital sanders but also stood out for their low-vibration and user-friendly handling. Process times were shortened by 30 %, resulting in significantly faster production.

+48 %

tool life

-5x reduction

labor requirements

-30 %

process time

+36 %

profitability

These improvements allowed boats to be manufactured faster with less effort while maintaining consistent high surface quality. The reduced tool wear and extended tool life also lowered production costs.

Automotive Industry

Efficient Processing of Carbon Body Components

Lightweight yet robust materials like carbon are indispensable in the automotive industry, particularly for high-performance and luxury vehicles. Precision is paramount in manufacturing body components such as hoods, fenders, and spoilers.

Using TY POWER hand tools, Tyrolit extended tool life by an impressive 38 % during carbon component processing. This resulted in significantly fewer tool changes and a fivefold reduction in labor requirements. Process times were also shortened by 30 %, significantly enhancing production efficiency.

+38 %

tool life

-5x reduction

labor requirements

-30 %

process time

+36 %

profitability

Alongside increased production speed, customers benefited from improved surface quality. TY POWER machines replaced conventional random orbital sanders, offering not only a more user-friendly and low-vibration experience but also a longer lifespan for abrasive materials.

Aerospace

Automated Processing of Aircraft Exteriors

The aerospace industry demands exceptional surface quality and precision, particularly in the production of aircraft exteriors, which must be lightweight, aerodynamic, and stable.

Tyrolit achieved remarkable improvements through automation of the grinding process. For complex components like riveted aircraft exteriors, tool life increased by 51 %. Process times were simultaneously reduced by 25 %, significantly boosting productivity. Manual interventions were minimized, ensuring process safety and consistent end-product quality.

+51 %

tool life

-20 %

labor requirements

-25 %

process time

+24 %

profitability

These optimizations made production more efficient and reduced manufacturing costs. The comprehensive automation and reduced manual interventions also improved the working environment and made processes less error-prone.

Conclusion

Tyrolit offers innovative solutions in composite processing that allow customers to significantly increase efficiency, extend tool life, and reduce process times. This leads to higher productivity and improved surface quality of processed materials. In addition to substantial reductions in production costs, these innovations result in more environmentally friendly processes. 

Customers from diverse industries—from wind energy and automotive to aerospace and shipbuilding—have achieved impressive results with Tyrolit technologies. Let these successes inspire you and enhance the profitability of your composite processing operations.

Contact us

Contact us today for a no-obligation consultation and learn how Tyrolit can optimize your composite processing workflows:

Jörg Pfister
Head of Solutions Management Metal Industries

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