Efficient Production of Structural Composites for Moderate Volumes

Project time: 2014 – 2015

Budget: 3 055 000 SEK

Funding: FFI – Strategic Vehicle Research and Innovation

Composites are considered to have a central role in the solution of a number of challenges in the automotive industry where primarily the struggle to reach the statutory CO2 targets. Most available technologies for composites means, however, increased costs mainly due to material costs and long cycle times. Unlike these, the patented X-TECH™ technology is successfully developed to meet the cost target for applications suited to the automotive industry high volumes (> 50,000) where efficient production technology combined with high utilization of materials also gives weight reduction of up to 50% .
X-TECH™ is a technology that is based on a reinforcing skeleton of continuous fibers overmolded with a thermoplastic matrix. The current project has developed the development and manufacturing processes for the production of structural composites in volumes where the injection is not economically viable by utilizing the possibilities of PUR-RIM (reactive injection of polyurethane). Target volumes in the project have been 1000-10000.
Within the project, the technical production aspects evaluated as the important adhesion between reinforcement skeleton and matrix by different surface modifications. Properties, processability and costs were weighed to evaluate the best solution. To build the material models for developing simulation methodologies conducted a series of tests. The developed simulation methodology correlated by evaluating a simple test body.
Finally, verified both the development and manufacturing processes through the development of a demonstrator spongiform a cargo guards to a passenger car. Prototypes were developed which were tested both statically and dynamically in the form of standardized crash tests.
There developed protective grille met all technical requirements and reduced the weight by around 30% against the existing production grid. Additionally, composite solution, a design freedom which provides completely new opportunities to use the component as a design element in the interior of the car.
The project was a collaboration between Klippan Safety, INXIDE and Swerea SICOMP. Klippan Safety is a provider of security items for both heavy and light vehicles while INXIDE is the owner of the X-TECH ™ technology that develops and manufactures composite solutions for volume production. Swerea SICOMP is one of Europe’s leading research institute for polymer composites.

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