The pressure press technology was the winner of the Process/Assembly/Enabling Technologies category. The out-of-autoclave process is used for the 2014 Corvette Stingray sports car. System supplier was Globe Machine Manufacturing, material processor Plasan Carbon Composites. The material was supplied by Toray North America.
Winner of the category Process/Assembly/Enabling Technologies
Pressure press technology
OEM/vehicle: General Motors/2014 Corvette Stingray sports car
System supplier: Globe Machine Manufacturing
Material processor: Plasan Carbon Composites
Material supplier: Toray North America
Tooling/equipment supplier: Weber Manufacturing Technologies
Material/process: epoxy carbon fibre prepreg/pressure press
Pressure press process for carbon-reinforced composites (photos: SPE)
This is the first production use of a new rapid out-of-autoclave process for carbon fibre reinforced composites. It produces parts with equivalent mechanical properties and better aesthetics far faster (in 17 vs 150 min) than autoclaves, now making carbon composites affordable for medium-volume production. The patent-pending breakthrough reduces cycle time 66%, direct costs 30% and cost of process consumables 75%. Nickle-vapour-deposition (NVD) tooling with embedded hot-oil heating/cooling lines moves heat quickly through the Z-axis for rapid curing. A reusable silicone-rubber canopy reduces the cost and hassle of disposable bagging. Parts exit the tool with more consistent surfaces, reducing finishing operations 35%.
Finalist of the category Process/Assembly/Enabling Technologies
Lightweight seat pan
OEM/vehicle: General Motors/2013 Opel Astra OPC sports sedan
System supplier: SeaTcon
Material processor: Reinart
Material supplier: BASF
Material/process: Ultramid B3S & B3ZG8 PA 6/hybrid injection moulding
PA6 seat pan
Thermoplastic composite (PA6 with discontinuous and continuous fibreglass reinforcement) replaces stamped steel in this seat pan. It meets all safety requirements while improving crash and long-term fatigue performance, yet reduces wall thickness, packaging space and mass without increased cost. The part is produced in a hybrid injection moulding process combining robotic handling of pre-cut preimpregnated continuous-fibre inserts and an infrared heater inside the injection moulding tool that preheats and pre-forms the cold sheet prior to tool closure and overmoulding with impact-modified, discontinuous short glass/PA6, which is used to form ribs, edges and other geometry that long fibres cannot fill.
Finalist of the category Process/Assembly/Enabling Technologies
3.5l/3.7l V6 integrated coolant cross-over
OEM/vehicles: Ford Motor/2013 Ford Taurus, Flex, Edge, & Explorer & Lincoln MKZ, MKS, MKX, MKT vehicles
System supplier: ITW Tomco
Material processor: ITW Tomco
Material supplier: DuPont Performance Polymers
Material/process: Zytel HTN 51G35HSLR PPA & PA 6/injection moulding
Tooling/equipment supplier: Luttmann Mold
Integrated coolant cross-over tube
This integrated coolant cross-over tube eliminates corrosion from aggressive long-life coolants (LLCs) while taking 0.5kg (1lb) weight and €0.73 (US $1) cost out of each engine. Overmoulded brazed-metal tubing was replaced by injection-moulded 35% GR PPA tubing, which is subsequently inserted into a second tool and overmoulded with 30% GR PA6, forming the rest of the intake manifold. Significant structural design work was performed to ensure the hollow PPA tube would survive overmoulding pressures, and special mould-cavity pressuresensing technology from RJG helps prevent processing damage. The composite solution is recyclable, improves service life, fuel economy, and CO2 emissions while saving money.
