JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 32

awards

A moulding process that utilizes two-sided steel compression
Magna Exteriors Corp. has developed
a moulding process based on twosided steel compression. A proprietary,
fast-cure, high-Tg carbon fibre prepreg
using industrial-grade fibres was thus
developed. Parts are therefore suitable
for Class A applications.
The high-Tg formulations allow the
material to withstand heat from harsh
environments. The Tg also allows the
parts to be processed at the higher
temperatures (125°C) typically seen in
North American paint shops, compared to the typical European paint
shop temperatures (81°C).
Primary tooling was supplied by Cen-

tury Tool & Gage Co. of Fenton, Michigan. A modified tool design, based
loosely on conventional shear edge
compression tools, was also used. Modifications based on Fibersim analyses
were incorporated. Prepreg sheets are
cut to a 2D shape and then preformed,
using a proprietary end-of-arm tool
concept to achieve approximately 80%
of the final 3D shape.
With a cycle time measured in minutes
vs. conventional autoclave technology
where cycle time is in hours or days,
the process allows for higher volume
serial production, a factor to be considered in the automotive sector.

Innovative design for thermoplastic support frame structures:
Implementation of function-integrative hollow structures
As part of the TherMobility research
project - sponsored by the German
Federal Ministry for Economic Affairs
and Energy (BMWi) - the project
partners Rehau, Storck Bicycle and
the Institute of Lightweight Engineering and Polymer Technology (ILK),
TU Dresden, developed an innovative
design for thermoplastic support frame
structures. The frames can be manufactured in a highly automated, integrative
injection-compression moulding process
integrating local carbon fibre reinforcements. The technological implementation
of function-integrative thermoplastic
hollow structures offers high potential for
various applications. Novel manufacturing
processes for hollow structures made of
two functionalized half shells were tested
on a minibike demonstrator structure.
The aim of the project was to investigate and create a continuous process
chain beginning with the production of

function-integrated shell structures up to
the joined and painted hollow structure.
To keep production costs low and still be
able to reproduce the components at a
consistently high quality, both a
high degree of automation and
industrial-production-compatible manufacturing processes
were factored into this concept.
The load-adjusted use of
textile reinforcements in this
combined injection-compression moulding process offers
considerable potential in many
fields. The project involved
developing and characterizing
compatible textile thermoplastic sheets.
Using the same thermoplastic matrix for
both the sheets and the granulate made it
possible to reach the targeted high-quality
standards. The processing technology
used in the project offers a wide range
of forms, thereby constituting an ideal

32 jec composites magazine / No104 April - May 2016

Automotive
Winner: Polycon Industries, a division
of Magna Exteriors Corp. (Canada)
Partners: Barrday Composite Solutions
(Canada), Century Tool & Gage Co.
(USA)

E-Mobility
Winner: Institute of Lightweight Engineering and Polymer Technology, TU
Dresden (Germany)
Partners: Rehau AG + Co (Germany),
Storck Bicycle GmbH (Germany)

method to build functionalized, highly
integrative structures. The concept of a
shell structure consisting of two highly
functionalized parts generates particularly significant benefits in comparison to
similar structures. These structures can be
used in multiple vehicle classes for electric
mobility with various load requirements.
Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016
