Weight reduction by structural composite components - cost effective production in small, medium and large volumes by novel production processes

摘要

Weight reduction is a key factor in reducing the energy consumption of vehicles. The light weight potential of composite materials is well known and composites are widely used in high-end applications. Novel production processes enable now the production of structural composite components in a cost-efficient way. Simulation of component-structure and manufacturing allow an optimal design with respect to function and production of the component. Two different production processes, which are newly industrially introduced, are suitable for the production of mid and high-volume mass production. The E-LFT process combines the two elements of unidirectional endless-fiber-thermoplastic (EF) and long-fiber-thermoplastic (LFT) in a one shot process for high volume applications. E-LFT components are suitable to replace conventional metal components in production volumes up to 300'000 units/year and offer a weight reduction between 30 - 45%. The melting embossing process is suitable for high-structural components with defined and designed surfaces at low tool investment costs. Therefore these components are already cost competitive at volumes of 500 - 10'000 units/year. ESORO is deeply involved in both process developments, as well as in composite component design and simulation.