Development of a High-Volume Automotive CFRP Structural Component

From the Sketch to the Pilot Series

The starting point for the development project was a 2D sketch of a linear structural component to be installed in an e-vehicle at two different locations and functions. The pultrusion process had been selected as the manufacturing process. The load cases of the component were known as a further framework condition.

Prozessentwicklung: Detail Faser- und Textilführung | Fraunhofer
© Fraunhofer IGCV
Process development, detail: fiber and textile guidance

Process and Component Development

In close coordination with both industrial partners, the work included the design of the laminate structure, the selection of a suitable fiber-matrix system with special consideration of suitable multiaxial glass-carbon fiber textiles. The materials were qualified by upstream pultrusion tests. The multi-cavity pultrusion mold with associated closed injection and impregnation chamber was developed and manufactured by KraussMaffei. A particular challenge in the design of the pultrusion process was the guidance of the more than 800 carbon rovings and the numerous hybrid multiaxial textiles to the filigree hollow chamber structure of the profile.

Hybride Hohlkammer Strukturprofile | Hyundai
© Hyundai
Hybrid hollow chamber structural profiles

Transfer to the Customer and Series Production

After demonstration of TRL 5 on the IGCV pultrusion line, the entire process setup was transferred to a supplier in South Korea. The re-commissioning and training of the local staff was carried out by colleagues from C21. The mechanical performance of the pultruded components clearly exceed the requirements and are now in commercial series use at Hyundai.

Einsatzbereich Funktionintegriertes Strukturprofil | Hyundai
© Hyundai
Einsatzbereich Funktionintegriertes Strukturprofil | Hyundai

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  • Aerospace
  • Automotive and commercial vehicles

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