MATERIALS
is an application where composites can offer game-changing solutions over metallic alternatives. As well as reducing weight, composites also provide the opportunity for multifunctional designs in a single component, for example, with the addition of embedded insulation and/ or EMI shielding.
HISTORICAL PAIN POINTS Unfortunately, the laborious and costly manufacturing process for composites has been a significant barrier to many companies looking to adopt these materials. The challenge now is to be able to make them more cost effectively, and at a rate suitable for more widespread use. Until now, the most common advanced composites manufacturing process has been hand lay-up and autoclave curing, which entails a significant level of
highly skilled labour, and results in high quality parts but low throughput. Single parts often take hours or days to manufacture, including lengthy and energy-intensive curing steps. However, recent developments in production processes and automation, as well as the introduction of optimised resin chemistries, mean that this largely manual process has now been transformed into an automated workflow, helping to make high volume composite production a reality.
IN THE DRIVING SEAT WITH INNOVATION A novel manufacturing technique, which combines snap-cure resins and prepreg materials with press curing, is now allowing composite parts to be formed in just minutes. The process begins with in-house, high speed prepreg manufacture and automated ply cutting. This
❝ Composites can offer game- changing solutions over metallic alternatives.
Composite materials are desirable for transport applications due to their excellent chemical resistance and variability
is followed by moulding using an innovative system called Fast Press Cure, which stamps and cures the material in a fraction of the time previously required for thermosetting materials. The material is then automatically de-moulded, removed and passed onto final machining and post-moulding processes. This system enables the manufacture of composite components at speed, and is cost competitive compared to metallic alternatives. In addition, with an in- house prepreg line, materials can be tailored to each project specification, optimising the material and resin chemistries to provide the required fire, impact, electrical or insulative properties.
SUPPORTING SUSTAINABLE TRANSPORTATION This innovative process can operate at a cycle time suitable for medium to high volume manufacturing, as well as offering significantly more energy-efficient production than previous methods. This results in decreased production costs with a lower environmental impact. With this streamlined, efficient and cost- effective manufacturing process, composites can reach their full potential in high volume applications, and help to support the world’s transition to sustainable transport.
Composite materials can be tailored to specific applications
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Francis Arthur is the Engineering Manager at TRB Lightweight Structures.
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