JEC COMPOSITES MAGAZINE - Issue #66 - July/August 2011 - 34

thermoplastic

New processes for large-scale production of composite automotive applications
In conventional manufacturing processes, composite structures are formed in costly multistage process chains and joined in additional process steps such as gluing or welding. In terms of process engineering, the largest savings in mass production can be achieved by minimizing cycle times. Jacob has developed new processes, FITHybrid (JEC Award 2011) and SpriForm, which combine moulding, forming and joining processes for thermoplastic composites in a single large-scale process that is also cost-effective. The key benefit of the invention is that, in addition to the lightweight potential of composites, it offers the extraordinary potential of lightweight construction due to the combination with structural design.

DR.-ING. MARCUS SCHUCK, DIRECTOR OF RESEARCH & DEVELOPMENT JACOB PLASTICS GMBH

jec composites magazine / No66 July - August 2011
The technological feasibility of lightweight composite structure solutions that use a thermoforming process on continuous fibre-

n conventional manufacturing processes, lightweight hybrid composite structures are formed in multistage and therefore costly process chains, and joined in additional process steps such as gluing or welding. From a processengineering point of view, the largest savings in mass production can be achieved by minimizing cycle times. Over the past 3 years, with a series of pioneering projects, Jacob Plastics has developed a new production method which combines forming, moulding and joining processes in a single process step. This method combines the benefits of the individual processes, thus achieving a particularly high level of functional integration.

reinforced preforms has already been demonstrated. However, these materials involve processing constraints that limit design freedom for these structures, which hinders Fig. 1: General conditions for composite processes wider market penetration by this class of material. advantages of continuous fibre The constraints of the processes and reinforcement are combined with the materials used are illustrated in Figure design-freedom benefit of injection 1. moulding, making it possible to Combining the forming process used manufacture complex lightweight parts for fibre-reinforced preforms with in a one-shot process (see Figure 2). moulding processes such as injection, These innovations involve creating which offer greater design freedom closed or ribbed profiles to obtain but can result in a more limited range lightweight structures, which further of mechanical properties, should increases the lightweight-construction eliminate this conflict of aims. In potential of composite materials. To terms of lightweight construction, the meet complex product requirements,

JEC COMPOSITES MAGAZINE - Issue #66 - July/August 2011

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