Honda FCV features first hybrid-molded rear bumper beam

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  • One-shot molding technology enabled
  • Material layer combination enables easy material flow during molding process
  • 50% weight reduction compared to metal solution

The latest model of hydrogen electric vehicle from Honda Motor Co., the so-called “Clarity Fuel Cell”, has been recently introduced to the market. Using Tepex, continuous- and long-fiber reinforced thermoplastic composites with PA 6 matrix from company Bond-Laminates, in combination with a PA 6 grade (Durethan from Lanxess), Honda has introduced the world-first hybrid-molded rear bumper beam using one-shot molding technology.

50% weight reduction compared to metal solution

Lanxess has developed a one-shot hybrid molding process for making large components out of its plastic and glass fiber composite. The result is approximately 50 percent weight reduction compared to the metal solution and a significant streamlining of the production process.

Material layer combination enables easy material flow during molding process

The materials are composed in several layers in combination with Tepex dynalite, continuous long glass fiber reinforced thermoplastic composite sheets, and Tepex flowcore, random long glass fiber reinforced composite sheets. This combination enables an easy material flow during the molding process to fill out complicated part geometry. It also features higher mechanical strength with a superior characteristic of dynamic energy absorption in such a critical application as a rear bumper beam.

The series production of the Honda rear bumper beam is done by Takagi Seiko Co., a leading plastic parts manufacturer in Japan.

Tepex: composite material made from thermoplastic matrix and continuous fiber reinforcements

Tepex is a light yet strong composite material made from a thermoplastic matrix and continuous fiber reinforcements such as carbon or glass. It is used for automobile structural components such as front ends and seat shells, as well as in mass-produced items like smartphones and sporting goods. Tepex features cycle times of around 15 to 60 seconds, has reinforcing fibers and thermoplastic base material that provides very good mechanical properties.

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