Develops and manufactures sandwich panels and lightweight construction elements made of aluminium, GRP and composite materials in large formats.
Coratec AG
4617 Gunzgen (CH)New on Amplifa
About Coratec AG
Based in Gunzgen, Coratec AG has been developing, producing and distributing sandwich panels and composite panels for lightweight construction in the building, transport and industrial sectors since 1966. The technology is based on a material originally developed for aerospace; in the 1980s the company was part of Alusuisse, which shaped its expertise in handling aluminium face layers. Since 2004, Coratec AG has operated as an independent company. Production is carried out exclusively in a make-to-order process according to customer specifications – from product development and prototype manufacturing through to series production. Using hydraulic through-feed presses, an automated 3K-PUR adhesive application system and CNC machines, panels are produced in formats up to 10'300 × 3'000 mm, raw, CNC-machined or ready to install including assembly of assemblies. All manufacturing takes place in the company's own production hall in Switzerland; the products are used throughout Europe.
- Site
- Gunzgen
- Processes
- Manufacture of sandwich panels / composite panels (bonding of face layers, cores and inserts), Pressing/bonding with hydraulic through-feed presses (3K-PUR adhesive, automated 3K system), CNC machining (milling, drilling, contours, cutouts), Edge closures / edge sealing, Surface finishing: priming, painting, coating, anti-slip coating (ResaFloor R, Coil coating of aluminium face layers (powder coating and wet painting), Assembly of add-on parts and assemblies (e.g. blind rivet nuts, inserts, ready-to-install elements), Product development and prototyping (engineering, make-to-order)
- Materials
- Aluminium, GRP (glass-fibre reinforced plastic), Corapan core (in-house developed core), Aluminium honeycomb core (CORAHEX), PET foam (incl. recycled material, 70/100/150 kg/m³), XPS, PUR recycled material, PUR foam
- Founded
- 1966
- Industries
- Vehicle construction, Rail/rail vehicles, Shipbuilding/maritime, Construction, Industry, Defence and industrial containers
- 01
Product development and prototyping
- 02
Procurement from a large materials warehouse and supplier network
- 03
Bonding of face layers, cores and inserts (3K-PUR, hydraulic presses)
- 04
CNC machining
- 05
Edge closures, surface finishing
- 06
Assembly of add-on parts and assemblies
- 07
Delivery ready to install according to specification
Materials and processes
Aluminium
Face layers from stock-managed aluminium coils in widths of 1250 to 2630 mm, a core competence of the company since the Alusuisse era.
GRP (glass-fibre reinforced plastic)
Robust, impact-resistant and corrosion-resistant face layers in various versions, customisable from approx. 300 m².
Corapan core (in-house developed)
Proprietary core for lightweight panels with high-quality surface finish, optimised fire behaviour and dimensional stability.
Aluminium honeycomb core (CORAHEX)
Honeycomb core in densities of 40, 59 or 83 kg/m³ for maximum stiffness at low weight.
PET foam (70/100/150 kg/m³)
High-load core, also made from recycled material, for floors and heavily stressed applications.
Epoxy resin with glass or aramid fibres
Heated-press cured, high-strength structures with optimised fire behaviour (IMO) for technical applications.
XPS, PUR foam, PUR recycled material, PVC, HPL, Purenit, PP honeycomb, plywood
Individual core and face layer materials for customer-specific builds.
3K-PUR adhesive
Automatically applied adhesive for process-reliable bonding regardless of ambient conditions.
Steel, stainless steel
Face layer and insert material for special mechanical requirements.
Sites
Gunzgen
CHHeadquarters and production (own production hall)
- Part weight / size
- Formats up to 10'300 × 3'000 mm
- Lot size
- Project orders through to series production
- Materials
- Aluminium, GRP, composite materials, various core materials
- Hydraulic through-feed presses (heatable, formats up to 3 × 10,3 m)
- Automated 3K system (3K-PUR adhesive application)
- CNC machines (up to 3 × 8 m)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of sandwich panels / composite panels (bonding of face layers, cores and inserts)Joining | ±0,3 – ±2,0 mm (depending on dimensions) | 10'300 mm × 3'000 mm | – | Project orders through to prototypes – Series production | Aluminium, GRP, Steel, Stainless steel, HPL, PET, XPS, PUR recycled material, PUR foam, PVC, Honeycomb core (aluminium/aramid), PP honeycomb, Plywood |
| Pressing/bonding with hydraulic through-feed presses (3K-PUR adhesive, automated 3K system)Joining | – | 10'300 mm × 2'610 mm | – | – | Aluminium, GRP, fibre-reinforced plastics (epoxy resin with glass or |
| CNC machining (milling, drilling, contours, cutouts)Machining | – | 8'000 mm × 3'000 mm | – | – | Aluminium, GRP, Composite panels |
| Edge closures / edge sealingSurface | – | – | – | – | Aluminium, GRP |
| Surface finishing: priming, painting, coating, anti-slip coating (ResaFloor RSurface | – | – | – | – | Aluminium, GRP |
| Coil coating of aluminium face layers (powder coating and wet painting)Surface | – | 1600 mm (fire-protection coating) | Minimum quantity approx. 300 kg (powder | – | Aluminium |
| Assembly of add-on parts and assemblies (e.g. blind rivet nuts, inserts, ready-to-install elements)Assembly | – | – | – | – | Aluminium, GRP, Composite panels |
| Product development and prototyping (engineering, make-to-order)Engineering | – | 10'300 mm × 3'000 mm | – | Prototypes – Series production | Aluminium, GRP, Plastic, Composite materials |
| CORAHEX® – honeycomb core sandwich panel (aluminium honeycomb core, aluminium face layers)Moulding | ±2,0 mm (L/W), ±0,3 mm (thickness) | 10'300 mm × 2'610 mm | – | – | Aluminium |
| CORAPAN® AL 150 – sandwich panel with proprietary core for construction and railMoulding | ±2,0 mm (L/W), ±0,8 mm (thickness) | 9'500 mm × 2'610 mm | – | – | Aluminium |
| CORAPAN® AL 85 – lightweight aluminium sandwich panel for vehicle constructionMoulding | ±2,0 mm (L/W), ±0,8 mm (thickness) | 9'500 mm × 2'610 mm | – | – | Aluminium |
| CORAPET® AL – sandwich panel with PET foam and aluminiumMoulding | ±2,0 mm (L/W), ±0,5 mm (thickness) | 10'300 mm × 2'610 mm | – | – | Aluminium, PET foam |
| CORAPET® GRP – sandwich panel with PET foam and GRP face layersMoulding | ±2,0 mm (L/W), ±0,5 mm (thickness) | 10'300 mm × 2'900 mm | – | – | GRP, PET foam |
| Manufacture of heated-press cured structures with fibre-reinforced plastics (epoxy resin matrix,Plastics | – | – | – | – | Epoxy resin with glass fibres, Epoxy resin with aramid fibres, Aramid honeycomb, Aluminium honeycomb, PET foam |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Hydraulic through-feed presses (heatable) | – | – | Formats up to 3 × 10,3 m | – | Gunzgen, Switzerland |
| Automated 3K system (3K-PUR adhesive application) | – | – | – | – | Gunzgen, Switzerland |
| CNC machines | – | – | up to 3 × 8 m | – | Gunzgen, Switzerland |
Additional services
History
- 1966
Start with the development of a novel material for aerospace
- 1980
Coratec part of Alusuisse; build-up of expertise in handling aluminium face layers
- 2004
Separation from the large corporation structures; founding of the independent Coratec AG in Gunzgen
- 2000er–2010e
Product range expanded: self-supporting balcony floor with its own anti-slip coating, honeycomb panels in large formats, non-combustible products
- 2020er
Investments: hydraulic presses for formats up to 3 × 10,3 m, automated 3K-PUR adhesive application, CNC machines