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.
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.
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.
Greenhouse gas reduction through high-quality recycling processes and materials
The production of new carbon fibres is based on fossil raw materials and is very energy-intensive, making the recycling of the fibres all the more important. In the "Infinity" project, the fibre-friendly recycling process is demonstrated by means of a thermoplastic, structural component from the aviation sector, which can also be used to demonstrate material substitution.
more infoEconomic, technical and life cycle assessment of recycled carbon fibers in industrial processes.
Decision-making basis for the use of recycled carbon fibers: The central objective of the MAI ÖkoCaP project is to establish a reliable and transparent basis for decision-making that allows the benefits of using rCF in different industrial applications and products to be estimated.
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The project focuses on the ecologically sustainable design of structural construction methods and production technologies for future and existing helicopter structures.
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NATUR addresses lightweight construction methods and technologies for CFRP fuselage structures that contribute to reducing the global warming potential (GWP) along the entire process chain through the consistent use of material residues, recycled carbon fibers (rCF) and out-of-autoclave (OoA) prepregs, as well as associated energy-reduced production processes and systems. The focus is therefore on optimizing component design and production planning for a sustainable material cycle, as well as energy- and emission-optimized production control. The weight reduction also makes a significant contribution to reducing the environmental impact during the aircraft's service life.
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The overall objective of "Cider" is to develop sustainable, recyclable and recycled composite materials for the transport sector. This will be achieved through the development of three demonstrators over several life cycles of the fibre and polymer material.
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Process digitization in the IoT context is revolutionizing traditional processes through the integration of intelligent technologies. In the DIGIMAP project, a comprehensive IoT infrastructure is being set up that is adapted to the automated fiber placement (AFP) process. This enables precise analysis and optimization of the process steps and quality. The data collected and stored in the cloud will be used to create a product twin.
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Fraunhofer Institute for Casting, Composite and Processing Technology IGCV