Continental Structural Plastics (CSP) has improved its carbon fibre RTM (CF-RTM) process to the point of perfection. Due to this, a premium automaker has decided to use the technology for closures on future vehicle platforms. These doors will have both inner and outer panels as well as structural reinforcements molded using CSP’s advanced CF-RTM process.
When CSP set up its Centre of Excellence for Lightweight Technologies and Carbon Fibre Processes in Pouancé, France, in 2013, the goal was to develop processes to make the use of carbon fibre in high volume applications affordable and feasible. Since then, the CSP team in Europe has been working on developing a high-performance CF-RTM process that would result in high-strength, ultra-light-weight components to help OEMs address stringent carbon dioxide emissions regulations. Specifically, the team has been focused on improving cycle time, utilising automated preforming and lowering the cost of the carbon fibre materials.Continental Structural Plastics (CSP) has improved its carbon fibre RTM (CF-RTM) process to the point of perfection. Due to this, a premium automaker has decided to use the technology for closures on future vehicle platforms. These doors will have both inner and outer panels as well as structural reinforcements molded using CSP's advanced CF-RTM process.#
“We have been targeting a 3-minute cycle time using 100 per cent recycled carbon fibre. With our multi-material decklid concept, we demonstrated this was totally possible,” said Marc Philippe Toitgans, director, Research and Development CSP Europe. “Now we are proud to say we have collaborated with major OEMs in the United States and Europe on carbon fibre RTM programmes and will see the first commercial applications of this technology very soon.”
From CAE analysis, flow simulation, preform process, mold design and full automation, CSP has built best-in-class expertise to support major structural and Class A CF-RTM programmes for closures and other BIW applications.
CSP’s key differentiators are based on 100 bars of injection pressure, and up to 1,500 tons of pressure for closure applications; high fibre content (greater than 50 per cent) for structural applications; 20-second injection time; management of variable thicknesses; and weight savings of up to 30 per cent when compared to aluminium.
To support several carbon fibre RTM programmes, CSP and parent company Teijin are investing in a dedicated CF-RTM production line in Palmela, Portugal. The initial investment of €5.5 million will include the installation of compression presses, RTM injection units and a bonding cell.
“We are excited to be working hand-in-hand with our customers in Europe to demonstrate our RTM capabilities,” said Ricardo Barros, CSP/Inapal programme manager. “The level of industrialisation and automation we are installing in Palmela is second to none for similar carbon fibre applications.”
In addition to reducing component weight and cycle times, the CSP team in Europe has been pursuing a number of methodologies that will result in more sustainable manufacturing processes. Working toward a net zero emission target, CSP Europe is working on tomorrow’s CF-RTM process with a primary focus on natural or recycled fibres, thermoplastic/bio-sources, advanced resins, and reduced scrap and waste.
“Our goal is to keep working on a sustainable value proposition with a focus on net zero CO2 emissions,” said Philippe Bonte, president, CSP Europe. “We will achieve this via advanced manufacturing technologies and the use of renewable materials with the aim of becoming a positive contributor to the global environment.”
CSP had won a JEC Innovation Award in 2016 for its Lincoln MKS Decklid Concept – a TCA Ultra Lite outer panel and a carbon fibre RTM prototype inner.
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